In today’s industry, automation technologies have become indispensable for making production processes more efficient, faster, and less costly. Turnkey factory automation is a comprehensive solution that ensures a production facility is established from scratch with a fully functional automation system. This process covers all steps from planning the facility to the installation, integration, and commissioning of hardware and software systems. Factory automation is preferred in both large-scale industrial facilities and small and medium-sized enterprises to enhance efficiency and gain a competitive edge.

In this article, we will explore what turnkey factory automation is, its advantages, the installation process, and the key factors to consider for successful automation system implementation.

What is Turnkey Factory Automation?

Turnkey factory automation is the process of setting up and commissioning all the systems required for a production facility to operate entirely automatically, from start to finish. In such projects, the factory’s entire automation systems, production lines, control systems, and hardware and software needs are determined and provided as an integrated solution.

The term “turnkey” refers to the automation company managing the entire project from start to finish, delivering a fully operational system to the customer. Once the project is handed over, the factory is ready to operate at full capacity with minimal human intervention.

Advantages of Turnkey Factory Automation

Turnkey factory automation offers several advantages for businesses:

1. Increased Efficiency

Automation speeds up production processes and performs repetitive tasks quickly and without errors. This shortens production times and increases product output.

2. Cost Savings

Automating manual processes reduces labor costs, and minimizing errors in production processes lowers overall costs. Additionally, automation systems optimize energy consumption and resource usage, further reducing operational costs.

3. Error-Free and High-Quality Production

Automation systems prevent human errors and ensure consistency in production processes, enabling the production of high-quality and standardized products.

4. Flexibility and Adaptation

Turnkey automation solutions make production lines more flexible. When production needs change, the automation system can be adapted quickly. This makes it easier to increase production capacity or add new products to the production line.

5. Monitoring and Reporting

Automation systems allow for the monitoring of production processes and the generation of detailed reports. Data is collected and analyzed in real-time, allowing decision-makers to optimize processes.

6. Safety

Automated systems minimize human involvement in hazardous or difficult tasks, reducing the risk of workplace accidents and injuries. Automation systems improve worker safety, especially in industries involving hazardous chemicals, high temperatures, or heavy loads.

Turnkey Factory Automation Process

A turnkey factory automation project consists of several critical steps, which must be meticulously planned and executed from start to finish.

1. Needs Analysis and Planning

The first phase of the project involves a detailed analysis of the customer’s needs and the factory’s automation requirements. Considerations in this process include:

• Which stages of the production process will be automated?
• What types of robots, machines, and automation solutions will be used?
• What kind of control systems are needed?
• Is the existing facility infrastructure sufficient for automation?
• What are the production capacity targets?

This analysis phase is crucial for the success of the project. Proper planning can result in significant time and cost savings.

2. Design and Engineering

After the needs analysis, the design phase of the automation system begins. During this phase:

• The hardware, sensors, robots, and control systems to be used in the automation system are selected.
• The layout of the factory and the positioning of equipment are planned.
• Software such as PLC (Programmable Logic Controller), SCADA (Supervisory Control and Data Acquisition), and HMI (Human Machine Interface) is designed.
• Electrical and network connections are planned.

The design and engineering phase requires detailed work to ensure the system operates optimally for the needs. At this stage, the integration of each piece of equipment, robot, and control system used in the production line is also ensured.

3. Installation

Once the design and engineering process is completed, the physical installation phase begins. During this stage, the necessary equipment and machines are installed at the factory site, and the infrastructure is completed:

• Robots, machines, and transport systems are placed in the factory environment.
• Electrical, air, and data communication lines are laid.
• Sensors and other automation components are installed.

It is critical to adhere to safety and quality standards during installation. Additionally, tests are performed after installation to ensure all systems are functioning correctly.

4. Software Installation and Integration

Following the installation of hardware, the software that powers the automation system is installed. During this phase:

• PLC programs are written and tested.
• SCADA and HMI systems are installed, and the operator interface is created.
• The integration of all systems to work seamlessly together is ensured.

Software integration is vital for the smooth operation of the system. Additionally, a user-friendly interface is designed to allow operators to use the system efficiently.

5. Testing and Commissioning

Once all systems are installed, the testing phase begins. During this phase, all system components are activated, and their performance is tested. It is verified that the production line is functioning correctly and that the automation system is working as planned:

• Robots and machines are tested.
• Production processes are simulated to detect and resolve any errors or malfunctions.
• Sensors and control systems are verified.

Any issues encountered during testing are resolved, and the system is ensured to be operating at full capacity.

6. Personnel Training and Handover

In turnkey automation projects, after the system is commissioned, the training of the operating personnel is provided. Operators, maintenance teams, and managers are informed on how to use the system and how to intervene in case of issues. Training includes:

• Using the HMI (operator interface).
• Monitoring and managing the production line.
• Intervention methods for potential malfunctions.
• Maintenance and repair procedures.

After training is completed, the project is handed over to the customer, and the system begins operating at full capacity.

Key Considerations for a Successful Turnkey Automation Project

Several important factors should be considered for the success of turnkey factory automation projects:

• Strong Collaboration: A solid partnership between the automation provider and the business is essential. Needs and goals should be clearly defined, and continuous communication should be maintained.
• Future-Oriented Planning: Automation systems should not only meet current needs but also be flexible enough to adapt to future growth and changes.
• Quality Hardware and Software Selection: The quality of the equipment and software used is crucial for the performance of the automation system. Reliable and durable hardware should be preferred.
• Regular Maintenance and Support: Regular maintenance is necessary for the smooth operation of automation systems. Additionally, quick support should be available for potential malfunctions.

Turnkey factory automation is an ideal solution for increasing production efficiency, reducing costs, and improving quality in modern industrial facilities. A well-planned turnkey automation project provides businesses with a competitive advantage and the ability to adapt to future growth and changes.