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Archiwum dla miesiąca: February 2022

5 levels of automation

The last few years have brought us an incredible increase in automation in the service sector. Digital transformation has also strongly affected some industries – especially food. Manufactured products must be of good quality, be diverse and tailored to the needs of the customer, and the fact that these change quickly so we need for flexibility. The 5 levels of automation present the perspective of the company’s development, from manual processes through the gradual increase of robotization, to the harmonious autonomy of all systems.



Company diagnosis

To start the transformation towards Industry 4.0, it is first necessary to make a diagnosis of the company in terms of process advancement and digital maturity. You can also create the entire Roadmap to Industry 4.0, i.e. the entire strategy of the company’s development towards the implementation of an appropriate business model and new technologies.

5 levels of automation

  1. Manual production

Manual production is characterized by companies in which the machine of automation. The processes take place without integration, the data is collected in paper form and then entered into a spreadsheet.

Actions are based on strict procedures, manual actions.

  1. The beginnings of automation

Machines appear, simple conveyors, but they are unitary. Implementation of new devices is difficult because it requires greater qualifications from operators and new procedures. The data is still collected in paper form.  This level is often characterized by randomness – purchases of new machines are not dictated by the development strategy.

  1. Process development

More machines mean more advanced procedures, faster product manufacturing and greater repeatability. Automated value chains are emerging. At this stage, the company should already have a whole development and transformation strategy in place to avoid unnecessary or unsuccessful investments.

  1. Advanced automation

Processes and machines are arranged in specific cycles, are measurable, standardized and repeatable. The data is collected digitally and processed in such a way as to improve production. Employees mainly deal with processes that are difficult to automate, but their main task is to supervise the work of machines.

  1. Full integration of machines, processes and people

Full integration of  machines, processes and people is Industry 4.0. Machines and robots as well as automated production lines cover almost 100% of processes. The integration also includes production data collected in BigData and processed in the cloud. Scalability of production is possible at the highest level of quality.  Humans continue to control machines and processes and create new quality in value chains.


Other determinants of modern automation

The history of automation is over 100 years old. Since then, business models, technologies and supply chains have changed. What are the determinants of modern automation?

– Closed circulation of raw materials (water, energy, etc.)

– Energy efficiency

– Intelligent production

– Digitization of production, administrative and office processes

– Cybersecurity

– Leadership, project management and development strategy

– Employee education

If you want to contact us, write to us!




Production processes – factory automation

Production processes are all activities related to the production of products. These include the gradual completion or creation of the expected product in accordance with the design or process assumptions.


Types of production

The production of products is linked to a value chain that includes supply, technological processes, transport and storage. Types of production can be differentiated by nature, location or volume.

Production lines

The organization of processes is arranged sequentially,where subsequent stages follow each other, finally giving the finished product. Production lines can be manual, semi-automatic or fully automated and robotic. Highly efficient lines are usually geared towards the production of one or several different products. Efficiency comes from the speed of individual processes, and the transformation of tools to different products affects volumes. Lines that are adapted to the production of different products must be equipped with additional equipment that will allow them to handle products that differ, for example, in size.

                                Production is flexible

An example of such a solution is a line for the installation of lighting lamps. On a conveyor with several different stations, you can put one of the many types of positioning trolleys, which are adapted to specific lamp sizes. In this way, production is flexible and more products can be added – all you have to do is design and manufacture a new typeofproduct.

                               Nest production

Nest production is a more flexible variant of a traditional production line. Individual workstations or process stations are not permanently bound by the flow of the product. This means that we can produce different types and types of products by changing the order of the stations. This type of production is possible if some technological processes do not have to follow each other.


Our nest production concept has been applied to a factory in the furniture industry. We have unified all robotic stations, so they can be rearranged according to your needs. The most common products are manufactured on thehi-runnerline. On the other hand, all the others can be produced flexibly  by making  sockets in individual technological lines.

                                 Diffuse generation

Distributed production proved itself in the era of the pandemic, when various industries suffered from lockdown  or lack of raw materials. This type of manufacturing is not tied to a specific place. Based on 3D models, production can be subcontracted depending on the availability of human and material resources. This is where 3D printing and, for example, laser cutting work great. Distributed production allows you to save your own resources and make the customer independent of suppliers. New technologies  help to produce more and faster, but in this case the emphasis should be on the security of our data – i.e. digital libraries and data transfer, for example.


Production processes

Production processes

– mechanical – completing and assembling, twisting, assembly, cleaning, labeling

– chemical – gluing, dispensing  liquids and gaskets, UV curing, painting

– permanent joining of elements – welding, soldering

– machining – CNC, grinding

– testing – mechanical,pneumatic, electrical, EOL

– natural – resulting from the natural action of the forces of nature – drying, cooling, etc.

Production processes – preparation of raw materials, transport, packaging and palletizing.

How do we do it at Alnea? We have extensive experience in implementing production processes on automatic lines. The Horus 3D vision system developed by us allows for offsetting of production processes and additionally image analysis and control, which allows you to maintain the highest standards and key performance indicators – KPIs (Key Performance Indicators).

Need production line or robotic station? Contact us:


other news


To help children

We are happy to wait for spring, but many children are just waiting for recovery. The staggering price of drugs means that they can only be purchased thanks to the generosity of many people. For several years we have been joining the auction campaign for children – this time for Lila from Biskupiec and Eryk from Radziłów. We are assisted in this by the partners of the Automation and Robotization of Industry Conference.


We encourage you to take part in the auctions because we received really cool things.


– Polish men’s volleyball championship team t-shirt, gloves of Andrzej Wawrzyk – heavyweight boxer – Pepperl+Fuchs


– Power banks, pendrives, 3D smartphone occluaries, cups, chimneys – Balluff


– Puzzles, key chains, pens and lots of other gadgets – Schmalz, Fanuc, Alnea


Special thanks for the big heart for


Tomasz Michalski

Marek Lozowski

Jacek Grabowski

Łukasz Szczepkowski

Damian Rybczynski

Mateusz Amrozinski


As a family company, Alnea has already supported various social or sports initiatives – including OKSJ Nippon Judo Olsztyna, GKS Stawiguda football team, OSP Stawiguda and local events.

Also during the AiR Conference, we present awards to the most talented students of technical schools.


“As a business representative, I feel responsible for my small homeland. As a father, I want to support other parents in the fight for the health of their children – I consider it my duty” Krzysztof Kamiński


Alnea’s activities have already been awarded many times – Vector 2018, Laurel the Best of the Best 2019, Way tor Success 2020. Our activities for the benefit of the region, supporting entrepreneurship, development of technical education and implementation of new technologies are appreciated, although for us more than the award counts the effect, i.e. the development of our region in which we live.

If you want to contact us, write to us!