Which Production Processes Can Be Automated?

Which production processes can be automated? CPP PREMA's machine building and modernisation capabilities

Both individual repetitive operations and complete production sequences can be automated: material feeding, measuring, cutting, assembly, bonding, welding, testing, handling, packing and labelling. The starting point should not, however, be a ready-made machine type. It should be a specific production problem: an excessive cycle time, a bottleneck, inconsistent results, difficult quality control, physically demanding manual work or frequent failures of ageing equipment. Once the process has been analysed, it is possible to determine whether the right solution is a new special-purpose machine, the automation of one workstation or the modernisation of an existing system.

CPP PREMA designs, builds and commissions machines, workstations and production lines tailored to the material, product and organisation of a specific plant. The scope can include mechanical engineering, pneumatics, hydraulics, electrical systems, PLC and HMI controls, testing, installation and subsequent service support. Our complete capabilities are presented on the production process automation page.

When is production process automation worth considering?

Automation is justified when it solves a measurable process problem. The fact that a machine can replace a manual task is not sufficient on its own. The required output rate, quality level, available operating time, number of product variants and cost of the current method must also be defined.

A bottleneck is often the first warning sign. One manual stage cannot keep up with the preceding and subsequent operations, limiting the output of the entire line. Another problem may be quality that depends on an operator’s experience or fatigue. In this case, maximum speed does not have to be the primary automation objective. Repeatable length, force, torque, position, portion weight or process temperature may be more important.

Automation should also be analysed when a workstation requires repeated manual transfers, manual product counting, frequent handling of heavy components or work close to moving tools. In these applications, a properly designed machine can organise the process flow, reduce the number of actions performed by the operator and improve control over process parameters.

A separate case is an ageing machine whose mechanical structure remains fit for purpose but whose control system causes downtime. Obsolete components, poor diagnostics, recurring sensor failures or the inability to save recipes do not always mean that the entire machine must be replaced. The expected result and total cost of modernisation should first be compared with the full cost of replacement.

Which production processes can be automated?

The best candidates are repetitive processes that can be described using unambiguous parameters and clear acceptance conditions. They can range from simple material-handling movements to multi-stage operations involving processing, assembly, inspection and packing.

Material feeding, unwinding and handling

Automation can begin as early as the delivery of material to the working area. Depending on the product, a machine may collect material from a reel, roll, pallet, bin, vibratory feeder or conveyor. The system’s purpose is not merely to move the material. It must also orient it correctly, maintain proper guidance and transfer it to the next operation at the required time.

In reel-fed processes, important functions can include supporting and centring the reel, controlling its rotation, guiding the material through rollers, providing a buffer and controlling web tension. For rigid products, grippers, positioning, presence detection and protection of the surface against damage are generally more important.

The handling of wet and dry veneer is an example of a demanding application. A solution designed by CPP PREMA uses separate modules to transfer material layers and handle separators. Individual sections can carry out different stages of the process, demonstrating that automated handling does not have to mean one simple conveyor. It can involve managing the operation sequence, changing the gripper, handling pallets and placing delicate material in a controlled manner.

Measuring, cutting and material preparation

Automatic measuring and cutting is suitable when every product batch must maintain a defined dimension. The length may be set in a recipe, verified by an encoder or determined by the geometry of the mechanism. The cutting method must be selected according to the material properties, required edge quality and expected cycle time.

CPP PREMA has delivered solutions for cutting felt, polymer fibres, textiles, EPDM seals and metal components, among other materials. This range of applications demonstrates that there is no single universal cutting module. Flexible reel-fed material is guided differently from several fibre strands, while a workpiece that must be accurately clamped before machining requires another approach altogether.

The FlexiForm R2 workstation is a good example. It automates the handling, clamping and edge bevelling of metal workpieces. Its verified cycle time is 20–25 seconds, corresponding to an output of 140–180 pieces per hour. In this case, the result depends not only on the tool itself but on the coordinated operation of positioning, clamping, machining and workpiece discharge.

Folding, forming, bonding and welding

Material-joining operations can be integrated directly into an automatic cycle. A machine can form an overlap, align the ends of a product, dispense a defined quantity of adhesive, press the joined surfaces together or complete a welding operation. The parameters depend on the material, joint geometry, curing time and quality requirements.

In a machine for EPDM seals, the process includes feeding the profile, measuring the programmed length, cutting, dispensing adhesive and joining the ends. Textile solutions can combine material unwinding, overlap forming, welding, cutting the finished section, folding and stacking a defined number of products.

This approach is extended in the felt measuring, folding and packing line. Its successive stations measure the material, cut and fold it, wrap it in film, seal the package, apply a label, group the products and place the finished items in cartons.

Component assembly and press-fitting operations

Assembly automation is appropriate when the sequence is repeatable and correct execution can be verified using measurable criteria. A workstation can automatically feed small components, position them in a fixture, carry out a press-fitting or fastening operation and then transfer the product for inspection.

Where there are multiple product variants, relevant solutions include interchangeable fixtures, programs selected from the HMI, tooling-presence sensors and coded change parts. Solutions based on SMED principles reduce changeover time, while Poka-Yoke mechanisms reduce the risk of starting a cycle with the wrong workpiece or tooling. The specific safeguards must always be designed for the machine and its operating sequence.

Testing and in-cycle quality control

Quality control does not have to be a separate operation completed after production. If the acceptance criteria are unambiguous, measurement can be integrated directly into the workstation cycle. A machine can check component presence, position, force, torque, leak tightness, pressure or the execution of a specified motion sequence.

PressureFlex, a CPP PREMA workstation for repeatable hose leak testing, is one example. The equipment has four independent test sockets and can be adapted for components of different diameters. Another example is a test rig that repeatedly opens, closes and loads doors according to a defined test program.

In assembly projects, inspection can include measuring press-fitting force and tightening torque. The result can then be used to direct a product automatically to the OK outlet or the reject bin. This reduces the dependence of the assessment on the operator and links the inspection result to the actual machine cycle. The scope of data recording and product identification must be agreed before the project starts.

Weighing, portioning, packing and labelling

End-of-line operations can be integrated with earlier material processing so that the product leaves the line ready for storage or onward distribution. The scope can include weighing, forming a package from film, heat sealing, counting products, stacking, grouping, placing items in cartons, closing cartons and applying labels.

PolyCut Pro combines polymer-fibre loading, cutting, conveying, weighing and packing. The completed line achieves an output of 30 packs per minute. It is an example of a project in which the performance of the entire machine depends on the synchronisation of several technologies: mechanical cutting, conveying, portioning, heat sealing and controls.

Speed is not the only important factor in packing automation. The acceptable weight or count tolerance, pack size range, number of formats, method of supplying film and cartons, label content and finished-product discharge point must also be considered. Only then can the number of stations and the required level of operator involvement be defined.

Which materials and products can special-purpose machines handle?

A special-purpose machine can be adapted for flexible reel-fed material, loose fibres, elastomer profiles, metal workpieces or large stacks of panels. This does not mean, however, that one mechanism will suit every product. Material properties determine the required guidance, gripping, positioning, tooling and inspection methods.

Flexible materials may require tension control, compensation for changing reel diameter and protection against lateral movement. Loose fibres require stable conveying and a suitable portioning method. An EPDM seal can deform during feeding, which makes controlled guidance before cutting and bonding important. Wet veneer, in turn, requires a gripping method that does not damage its surface and allows successive layers to be separated safely.

CPP PREMA has designed solutions for processes involving:

felt, nonwoven materials and textiles – unwinding, measuring, cutting, welding, folding and packing;
polymer fibres – feeding several strands, cutting, conveying, weighing and packing;
EPDM profiles and seals – measuring, cutting, adhesive dispensing and joining;
veneer and panel materials – gripping, turning, separating and pallet handling;
metal workpieces – clamping, bevelling, assembly and parameter inspection;
hoses – automatic pressure and leak-tightness testing;
cartons and packaging – forming, pressing, grouping, closing and labelling.

Before a concept is developed, it is worth providing material samples, drawings, tolerance information and a video showing the current operation. A test performed with the actual material can reveal issues that are not apparent from a 3D model alone, such as deformation, adhesion, a changing coefficient of friction or variation between batches.

From one automated operation to a complete production line

The project scope does not have to cover the entire process from the outset. In many plants, the best first step is to eliminate one bottleneck. In other cases, only the integration of several successive operations produces the required result because manual transfer would continue to limit the output rate and repeatability.

Automation of a single operation

This could be a workstation for cutting and joining seals, bevelling a workpiece or pressing cartons on a pallet. The operator still supplies the semi-finished product and collects the completed item, while the machine performs the operation that requires a repeatable position, force, travel distance or duration.

Multi-operation workstation

If a product passes through several related tasks, an indexing table, conveyor system or sequence of fixtures can be used. Individual stations can be responsible for feeding, assembly, measurement and unloading. The product no longer has to be put down and picked up manually several times, and the controller supervises the process sequence.

Complete production line

A line can start with raw material supplied from a reel, pallet or bin and finish with a labelled product placed in its packaging. This solution requires the synchronisation of drives, sensors, conveyors, controls and operating procedures. Buffer states are also important: stopping one station should not cause uncontrolled material accumulation elsewhere in the line.

Modular machine and phased implementation

A modular design makes it possible to divide the process into functional sections, such as material preparation, processing, inspection and packing. If this is planned during the design stage, individual modules can operate independently or be expanded during a later investment phase.

Not every machine can be extended later without changes to its mechanical design, controls and safety system. If the plant anticipates higher future output, new formats or an additional inspection station, this information should be provided during concept development. The successive stages are discussed in more detail in our comprehensive guide to mechanical engineering.

How can a machine handle different product variants?

Several formats can be supported if the complete range of variants is defined before the machine is designed. The differences may involve length, width, weight, material, operation position, packing method or quality-control criteria.

Process parameters can be stored as recipes selected from the HMI. A recipe can define the cutting dimension, speed, position, pressure value, number of pieces in a group or test procedure. A program alone is not sufficient, however, when the product geometry changes. Guides may need to be adjusted, or a fixture, gripper or tool may need to be replaced.

Frequently changed-over workstations can incorporate:

interchangeable fixtures and tooling adapted to a specific product variant;
coded change parts so that the controller recognises the selected variant;
presence and position sensors that prevent a cycle from starting with an incorrectly installed component;
adjustable guides and datum points that simplify format setting;
HMI changeover instructions that guide the operator through each step;
SMED and Poka-Yoke solutions that shorten changeovers and reduce the risk of errors.

Cycle time should be assessed together with changeover time. A very fast machine will not deliver the expected result if a format change takes too long, requires multiple adjustments or generates excessive rejects after restart.

A new machine, partial automation or modernisation of existing equipment?

The choice should be based on the condition of the existing equipment, the required result and the total implementation cost. Not every problem requires a new line. Conversely, retaining worn or unsuitable mechanical systems can limit the benefits of even the best control system.

When is a new special-purpose machine required?

A new machine is justified when a plant is introducing a process for which it has no suitable workstation, or when the existing structure cannot achieve the required output rate, accuracy or range of movement. A new machine makes it possible to design the ergonomics, product-feeding method, number of stations, control system and service access from the ground up.

If standard equipment available on the market cannot handle an unusual material, several formats or the required operation sequence, the answer may be a custom special-purpose machine and production automation solution.

When is the automation of one workstation sufficient?

Partial automation is appropriate when most of the process works correctly but one operation limits the entire line. This may involve manual adhesive dispensing, repetitive cutting, testing every product, moving a heavy component or packing. A limited scope makes the result easier to evaluate and reduces the number of interfaces with the rest of the production system.

When should an existing machine be modernised?

Modernisation is a rational option when the mechanical structure remains fit for operation but the other systems no longer meet the plant’s current needs. The scope may include PLC and HMI controls, electrical cabinets, drives, hydraulics, pneumatics, sensors, diagnostics and selected safety functions.

Before a decision is made, the following should be checked:

the condition of the frame, guides, working system and load-bearing components;
the availability of technical documentation and spare parts;
failure frequency and the actual time required for diagnosis;
whether the mechanical system can be adapted to new formats or process parameters;
the required accuracy, output rate and anticipated machine load;
the scope of changes required in the safety system;
the planned remaining service life and the available downtime window.

Hydraulic press modernisation – a technical example from CPP PREMA

Buying a new press is not always the most cost-effective option. If the machine structure remains serviceable, the components that continue to meet the process requirements can be retained. The budget can then be directed towards the systems that actually require rebuilding: hydraulics, controls, diagnostics and safeguards.

In a project completed by CPP PREMA, the existing press structure was retained. The technical scope of the modernisation included:

overhaul of the cylinder responsible for the working movement;
a new hydraulic power unit rated up to 320 bar;
PWM-controlled valves for speed and pressure regulation;
oil cooling and measurement of oil level, temperature and pressure;
new control cabinets with a SAFETY controller from the S7-1200 family;
a 10-inch ASTRAADA operator panel;
RFID sensors protecting the sliding guards.

Following modernisation, the press can operate in manual, semi-automatic and automatic modes. From the operator panel, the user sets the movement speed, deceleration threshold, pressing position and required pressure. The control system supports recipes, regulates tool temperature, measures cylinder extension and archives process parameters on a USB storage device.

The system controls pump operation automatically and disconnects the drives when the safety circuits are activated. The diagnostics provide operators and maintenance personnel with more information about the system’s condition than was available from the original controls.

What can a plant gain by modernising a machine?

The result is more than simply replacing old components with new ones. A properly planned modernisation can provide:

continued use of the existing structure and workstation infrastructure;
access to process parameters and faster diagnostics;
repeatable settings through saved recipes;
better monitoring of the hydraulic system’s condition;
a lower risk of downtime caused by obsolete controls;
adaptation of machine operation to new products or process requirements;
rebuilding of the safety functions within the scope defined for the particular project.

We do not provide one universal savings percentage for every modernisation. The result depends on the machine’s technical condition, the scope of work and the required outcome. The cost of modernisation should be compared with the full cost of replacement: the price of the new machine, removal of the old one, transport, workstation preparation, integration, commissioning and the cost of production downtime.

Which engineering disciplines must be combined when building a machine?

A special-purpose machine operates as one system, so its mechanical design, drives, controls and safeguards cannot be engineered in isolation. A change in gripper geometry affects axis movement, the required cycle time, sensor selection and the controller program. A change in the number of product variants may in turn require different fixtures, recipes and changeover procedures.

CPP PREMA combines the following project capabilities:

process analysis and concept development – understanding the material, output rate, constraints and required result;
mechanical engineering – the machine model, tooling, manufacturing drawings and service access;
pneumatics and hydraulics – selection of actuators, valves, medium preparation and control methods;
electrical systems, PLC and HMI – control cabinets, sensors, drives, programs, recipes and diagnostic messages;
assembly and testing – machine assembly, functional testing and preliminary acceptance;
commissioning at the customer’s plant – installation, checking interaction with the target process and final acceptance;
documentation and support – documentation within the agreed scope, service and subsequent modernisation.

Examples of completed equipment are available in our portfolio of production automation projects, machines and workstations. The portfolio should be viewed as evidence of engineering capability, not as a catalogue of fixed machine designs. Every new project must be adapted to the product and the operating conditions at the plant.

How should a process be prepared for analysis and an initial concept?

A complete machine specification is not required for the first discussion. An accurate description of the existing process, the problem and the required result is much more important. The machine builder should understand what happens to the product before the planned workstation and how it must be transferred to the next operation.

Before making contact, it is worth preparing:

a short description of the steps currently performed by the operator;
photographs and a video showing the entire cycle, not only the workstation;
drawings, models or samples of the product and material;
dimensions, weight, tolerances and properties that may affect gripping or processing;
the number of product variants and how frequently they are changed;
the current cycle time, required output rate and volume per shift;
the number of shifts and anticipated workstation utilisation;
quality criteria and the method for distinguishing OK and NOK products;
information about rejects, rework, downtime and failures;
available space, utilities and transport constraints;
the required communication with other machines or a supervisory system;
whether the project concerns a new machine or reuse of an existing structure.

It is also worth defining a measurable condition for project success. This might be achieving a specified cycle time, reducing rejects, limiting manual transfers, automatically inspecting every product or shortening changeover time. Without such an objective, it is difficult to determine whether the proposed concept solves the right problem.

Frequently asked questions about machine automation and modernisation

Which production processes are easiest to automate?

Repetitive operations with a fixed sequence and measurable acceptance parameters are generally the easiest to describe and automate. These may include feeding, measuring, cutting, assembly, testing, sorting or packing. The final assessment must nevertheless consider the material, number of variants and required output rate.

Can only one bottleneck be automated?

Yes. Automating one operation is often the best first stage when the rest of the process works correctly. It is still necessary to check whether the workstation’s higher output will merely move the bottleneck to the next stage of the line.

Can one machine handle several product variants?

Yes, provided that the range of variants is included in the design requirements. A change can be made by selecting a recipe, adjusting guides or replacing a fixture and tooling. The number of formats affects the mechanical design, control program, changeover time and equipment cost.

Can quality control be integrated into the machine cycle?

Yes, if the acceptance criteria can be measured using suitable sensors or measurement systems. A workstation can check component presence, force, torque, position, pressure or leak tightness and then separate OK and NOK products.

Does CPP PREMA automate reel-fed material processes?

Yes. Completed solutions include measuring, cutting, folding, welding and packing felt, nonwovens and other flexible materials. The guidance and processing method must always be adapted to the width, thickness, stretch and behaviour of the specific material.

When is modernisation better than buying a new machine?

Modernisation should be considered when the machine’s mechanical systems remain serviceable and capable of performing the required process, while the controls, drives, hydraulics, diagnostics or availability of parts have become the problem. The decision should be based on a technical assessment and comparison of the full costs of both options.

Which parts of an existing machine can be retained?

Components can be retained if their condition, parameters and anticipated durability are compatible with future use. The frame, working system, guides, cylinders, drives and installations are usually assessed. The final scope is defined after an inspection and review of the documentation.

Can an automation project be divided into stages?

Yes, if the mechanical and control architecture is prepared for future expansion. The first stage can address the main bottleneck, followed later by feeding, inspection or packing. The possibility of expansion must be agreed before the first stage is built.

How long does it take to build a special-purpose machine?

The lead time depends on process complexity, the number of stations, the need for trials, component availability, the documentation scope and commissioning at the customer’s plant. A reliable schedule can only be prepared after the technical assumptions and each party’s responsibilities have been agreed.

What information is required to prepare an initial concept?

The most important items are a process description, video, product samples or drawings, required output rate, number of variants, quality criteria and available space. The discussion does not need to start with a finished machine specification. The problem to be solved should be described precisely first.

The machine should follow the process, not the other way round

CPP PREMA’s production capabilities cover both individual workstations and multi-stage lines integrating handling, processing, assembly, inspection and packing. Modernisation of existing equipment is an equally important part of the offering when the machine structure still has the potential for continued operation.

The best project does not start with the question, “What machine can we build?” It starts by determining, “What is limiting the current process, and what result do we want to achieve?” Only then is it possible to compare a new machine, partial automation and modernisation and select a scope that is technically and economically justified.

You do not need to have complete machine documentation. Prepare a description of the process, photographs or a video, basic product data and the expected result. Send the materials to the automation team at export@cpp-prema.pl, use the English contact page or begin with an overview of CPP PREMA’s production automation capabilities.

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