In the workshop of a modern factory, the roar of machines is no longer a cacophonous noise, but an
industrial symphony of precision collaboration. When conveyor belts stop accurately, robotic arms grab
seamlessly, and quality control systems make millisecond decisions, industrial automation has gone from
a blueprint to a realistic productivity engine. However, transforming the vision of automation into a stable
and efficient operating system is far from being as simple as purchasing equipment and connecting lines.
It is a systematic project that requires meticulous planning, professional execution and continuous optimization.
This guide aims to reveal the core practical points for successful implementation of industrial automation.
Step 1: Define the goal - automation is not an end, but a means.
Driven by Pain Points: Define the core problem that automation is trying to solve:
Is it dealing with labor shortages and rising costs?
Is it to improve the capacity of specific bottleneck processes?
Is it to solve the high precision, high consistency of manual work difficult to achieve the quality requirements?
Is it to improve safety in dangerous and harsh environments?
Is it to reduce high scrap rates or energy consumption in a specific process?
Quantitative Metrics: Set clear, measurable success criteria:
Percentage (%) of target capacity improvement
Expected labor savings in volume or cost
Target yield improvement (PPM defect rate reduction)
Target energy consumption reduction per unit of product (%)
Expected return on investment (ROI)
Scoping: Define the boundaries of the automation project. Is it a single station retrofit? Whole line upgrade? Or
workshop-level linkage? Avoid “greedy for the whole”, focus on the core value of the region.
Step 2: In-depth site survey - understanding the “soil” in order to
accurately plant seeds
Process deconstruction: Record in detail the existing process steps, operating time, material flow, fixtures and fittings,
and beat requirements. Drawing clear process flow diagrams.
Physical space mapping: Accurately measure equipment layout, space dimensions (height, width, access), floor loading,
location and capacity of energy connections (power, gas, water), network cabling conditions. Consider future maintenance space.
Environmental factors assessment: temperature, humidity, dust, oil, vibration, electromagnetic interference and other
environmental factors directly affect the equipment selection and protection level (IP rating).
Existing equipment and systems: Inventory of existing depreciable equipment (PLC models, communication protocols),
control systems (SCADA/DCS/MES) interface capabilities, data collection basis. Evaluate compatibility and integration
difficulties.
Step 3: System Design and Technology Selection - Matching Demand,
Building a Robust Skeleton
Automation layer planning:
Execution layer: Select appropriate robots (articulated arm, SCARA, Delta, collaborative), specialized machines (automatic
screw locking, dispensing, welding), and conveyor systems (belts, rollers, doubled-speed chains, AGV/AMR) according to
the tasks.
Sensing layer: Select accurate and reliable sensors (photoelectricity, proximity, vision, force control, RFID, etc.) to ensure
stable sensing of the environment and workpiece status.
Control layer: Selection of core brain (PLC, PAC, industrial PC), considering the number of I/O points, processing speed,
communication capability, redundancy requirements, programming environment familiarity.
Network layer: Design of reliable, real-time, safe industrial network (Industrial Ethernet such as EtherNet/IP, Profinet,
EtherCAT, TSN), considering bandwidth, latency, anti-interference ability, topology (star, ring).
Human-computer interaction layer: HMI/SCADA interface design needs to be intuitive, easy to operate, clear
information hierarchy, easy for operators to monitor and intervene.
Information layer: Planning data interfaces (OPC UA, MQTT, API, etc.) with upper-level systems (MES/ERP) to
ensure smooth information flow.
Key selection principles:
Priority of applicability: Do not blindly pursue the “grand”, choose the most suitable technical solutions to match
the process requirements and budget.
Reliability first: In the harsh industrial environment, give priority to brands and components that have been proven,
have a good reputation and localized service support.
Openness and compatibility: Ensure effective communication and integration between different brands of equipment
and systems to avoid being tied to a single supplier.
Scalability and Flexibility: Reserve space for interfaces and capabilities for possible future line adjustments, capacity
expansion or product changes.
Safety compliance: Strictly comply with mechanical safety (ISO 12100, ISO 13849), electrical safety, functional safety
(IEC 61508, IEC 62061) and other standards, conduct risk assessment (RA), and design the necessary safety circuits (safety
relays, safety PLCs) and guards (light barriers, safety door locks, emergency stops).
Step 4: Integration, commissioning and validation - from drawing to stable
operation
Integration in phases: Follow the principle of “hardware before software, stand-alone machine before joint adjustment”.
Ensure stable mechanical installation, no leakage of air/liquid lines, and accurate electrical wiring.
Modular debugging:
Single-point test: Test the signal status and function of each sensor, actuator and I/O point one by one.
Function block test: Closed-loop debugging of independent sub-functions (such as loading, processing, discharging).
Online debugging: Open up the whole line or station automation process, focusing on verifying the synergy between
equipment, beat matching, and exception handling logic.
Comprehensive verification (FAT & SAT):
Operational stability (fault-free continuous operation time)
Achievement of beat/capacity
Product Quality Conformity
Safety function effectiveness
Human-computer interaction friendliness
Factory Acceptance Test: Simulate the operation at the equipment supplier to verify whether the core functions meet the standard.
Field acceptance test: At the user's factory site, using real materials (or substitutes), under the target production speed for
a long time (e.g., 72 hours) continuous operation test. Rigorous evaluation:
Detailed Documentation: Simultaneous updating and delivery of complete drawings (electrical, pneumatic, mechanical),
program source code (with comments), operation manuals, maintenance manuals, spare parts lists.
The fifth step: personnel empowerment and continuous optimization - so
that the system really “live” up!
Hierarchical training:
Operators: Skilled in the use of HMI interface, mastering the daily start and stop, change type, basic fault reset.
Maintenance personnel: in-depth understanding of the system principle, master preventive maintenance (PM) process,
common fault diagnosis and troubleshooting methods, spare parts replacement.
Engineers: have the ability to understand program logic, parameter adjustment, simple function optimization and
collaborate with suppliers to solve complex problems.
Establish maintenance system:
Develop and implement preventive maintenance programs such as periodic spot checks, lubrication, cleaning, etc.
Establish a closed loop mechanism for fault recording, analysis and feedback.
Manage critical spare parts inventory.
Data-driven optimization:
Utilize SCADA/MES system to collect operational data (OEE, downtime, quality data, energy consumption).
Analyze bottlenecks and continuously optimize in small steps: optimize program logic, adjust parameters, improve jigs
and fixtures, and improve changeover efficiency.
Critical Success Factors and Guidelines for Avoiding Pitfalls
Cross-Departmental Collaboration: Automation projects are not the sole responsibility of the equipment or engineering
departments, but must be supported by production, process, quality, IT, finance, and other departments, as well as senior
management.
Embrace change management: Automation will change the way we work, so we need to communicate this in advance and
focus on transitioning people to overcome resistance.
Emphasis on the “first kilometer” and “last kilometer”: automated production line on the consistency of incoming materials,
tooling positioning accuracy requirements are extremely high. At the same time, after the finished product off the line, packaging,
palletizing and other links of automation also need to be carefully considered.
Choose a reliable partner: The integrator's experience, technical strength, industry understanding, and local service
responsiveness are critical. Clearly define the boundaries of responsibility between both parties.
Allow for a buffer: Allow for a reasonable margin in budget and time (10-15% is usually recommended) to deal with unforeseen
challenges.
Success in industrial automation is the culmination of rigorous engineering thinking, a deep understanding of the process,
cross-discipline collaboration, and a relentless attention to detail. It is not a one-time equipment installation, but a journey
that requires continuous investment and refined iteration. By following the above practical paths and avoiding common pitfalls,
we can turn the blueprint of automation into a solid force that drives the competitiveness of enterprises to jump up, and move
forward steadily in the wave of intelligent manufacturing.