Individual Automation Solutions for SMEs Efficiency Through Customized Production Lines

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Micros Automation GmbH

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Automation solutions are the key for many medium-sized companies to succeed in an increasingly competitive market environment. This requires an understanding of the challenges faced by medium-sized businesses and the ability to provide automation solutions that are both economically and technically convincing.

The automation of industrial processes is no longer a privilege of large industries. Medium-sized manufacturing and assembly companies are also increasingly recognizing the strategic importance of efficient, comprehensive automation solutions. The reasons are varied: rising energy costs, increasing labor shortages, and growing quality requirements force companies to rethink production processes. "In the end, solutions for automating entire production lines reduce the need for personnel resources, increase efficiency, and ensure quality. This is a decisive competitive factor today," explains Michael Ott, Head of Sales at Micros Automation, a specialist in the planning and implementation of customized automation solutions in special machine construction based in South Tyrol.

Challenge: Individual Processes, Limited Resources

Especially in medium-sized companies, production processes have often evolved individually and are characterized by partially automated stand-alone solutions or even manual work. Both variants tie up capacities and prevent companies from fully realizing their potential. In light of this, the endeavor to establish comprehensive automation itself becomes a challenge. "Many medium-sized companies do not have the internal capacities to develop complex automation solutions for their entire process lines themselves," says Michael Ott. "What is needed is not just a machine manufacturer, but a specialized implementation partner who understands the big picture and, with their holistic expertise, also provides technological impetus."

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A central issue is that resources in areas like manufacturing engineering are often limited. Moreover, standard solutions rarely meet the specific requirements of medium-sized businesses. Michael Ott emphasizes, "Medium-sized businesses are very often faced with the situation that can be summed up as follows: 'I don't need an off-the-shelf machine, but someone who understands and solves my specific problem.' This is precisely where successful implementation must start, to approach automation holistically—and not just at individual points like a single machine."

The need for flexibility is often accompanied by uncertainty for medium-sized companies: "What is technologically feasible?" or "What investments are necessary?" are questions that frequently arise. Therefore, it is important, as Michael Ott states, that implementation partners do not simply act as suppliers but explore solutions collaboratively with the respective medium-sized company. Only in this way can sustainable solutions be developed.

Structured Process in Five Phases

For example, Micros Automation operates with a clearly structured five-phase model: from the analysis of the task to concept creation and verification, and finally to the realization of the final machine. The foundation is the concept and performance specification, which is created in an early project phase. It includes the customer requirements, an initial layout, and a budget estimate of the automated process line.

"Apart from determining the requirements and information necessary to comprehensively automate a process line, this also serves another purpose: exploring potential synergies that have so far remained unrecognized," explains Michael Ott. It is particularly important to technically verify solutions together with the product developers on the respective company's side. "This ensures that the final concept is not only technically feasible but also considers all product-specific requirements." Transparency is considered a key to success: "Clarity about what is realistic—both technically and economically—is highly relevant. This significantly reduces risks on both sides."

Modularity Creates Flexibility and Efficiency

An essential element of the individual automation approach is also the modular machine architecture. Systems consist of standardized base modules into which individual components are integrated, allowing production lines to be tailored to the user, their requirements, and budget. This not only speeds up setup and commissioning but also reduces transportation risks.

This avoids an approach with rigid basic machines. Instead, a situational decision is made about which concept—whether rotary table, workpiece carrier, or transfer line—is best suited for the respective process. "Compared to classic systems, this flexibility presents a significant advantage, as it comes closest to a tailor-made production line," explains Michael Ott. Such an architecture also allows for individual modules to be expanded or replaced if necessary. This enables adaptation to changes in the production process without the immediate need for a completely new system.

Wide Technology Spectrum: from Robotics to Camera Technology

Modern automation systems for assembly, handling, testing, and packaging increasingly rely on a high degree of automation while simultaneously reducing personnel deployment. The goal is to create seamless production lines in which delivered individual components are fully automated into ready-to-install products.

Various technologies are employed here: robots perform precise and repeatable handling tasks, intelligent sensor technology controls processes in real-time, and camera-based inspection systems ensure comprehensive quality assurance. "The camera serves as the 'eye' of the system. It detects whether a part is placed correctly, whether it is defect-free, and directly sends this information to the control system," explains Michael Ott. The technological spectrum is complemented by modern control and visualization solutions that make complex processes manageable while enabling user-friendly operation. The aim is to achieve the most intuitive operability of systems possible.

Advantages for SMEs

The advantages for medium-sized companies are clear: consistent, higher output, consistent quality, reduced personnel needs, and thus more planning security. Automation relieves monotonous, non-value-adding tasks while simultaneously increasing productivity.

"Through automation, a machine or production line ultimately delivers consistently the same performance—regardless of sickness, shift systems, or motivation. Especially in times of labor shortages, this is an invaluable advantage," says Michael Ott. Added to this are positive effects on the work environment: employees can focus on value-added and interesting tasks while routine activities run automatically. "This also increases team motivation," adds Michael Ott.

Use in Different Industries

Individual automation solutions find application in a variety of industries. Whether in powertrain and steering systems in the automotive sector, in the machining of die-cast parts for e-mobility, or in plastic injection molding parts and packaging processes in the food industry; wherever high quality requirements need to be combined with efficiency and flexibility, customized systems are in demand. This opens up the possibility to adapt proven technologies from different industries to new fields of application. However, the key to implementation is primarily the close integration of all project participants. Short distances and interdisciplinary teams promote exchange and accelerate development processes.

Trends: Energy Efficiency and Demographic Change

Even in light of current megatrends, automation is a central issue. "Energy efficiency in production is becoming increasingly important. Therefore, solutions that design processes in a resource-saving manner and minimize energy use are increasingly in demand," says Michael Ott. Another driver is the demographic change; the availability of skilled personnel is steadily declining. Automation is therefore not only a matter of efficiency but also of the future viability of companies and how the deficit of personnel can be compensated with automated systems. At the same time, flexible investment concepts are gaining importance. "Many products are difficult or uncertain to estimate in their lifecycle. Companies therefore need automation solutions that can be modularly expanded or adjusted—without major new investments," says Michael Ott.

Conclusion

The SME sector faces profound upheavals. The challenges are complex: The labor shortage is growing, demands for efficiency and quality are increasing, and ecological aspects are becoming increasingly important. At the same time, investments in automation must be economically viable and technologically future-proof.

It becomes evident that well-conceived automation solutions are already capable of managing this balancing act. A continuous approach is crucial: from structured analysis to modular plant concepts and the use of the latest technologies such as robotics, camera technology, and intelligent control systems. Those who understand the automation process as a partnership development not only establish stable processes but also gain flexibility and competitiveness. "The key point is that it's not just about delivering technology, but solving a very specific problem. It's important to think in terms of processes and user benefits, rather than just machines," summarizes Michael Ott.

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