Cycle time is often treated like a single number to chase, but the reality is more nuanced. A faster move profile means little if the cell stops every hour for a minor fault, or if operators cannot access the area safely to clear a jam. That is why Robot Cell Design needs to balance performance with safe, repeatable operation. At Premier Automation, we design and build new robot systems, integrate used robots, and re-engineer existing cells to reduce cycle time while keeping safety and uptime at the centre of the project.
The best improvements usually come from removing hidden inefficiencies: slow part presentation, awkward handshakes with machines, unnecessary robot travel, changeovers that take too long, or safety systems that create nuisance trips. By taking a whole-cell view, you can achieve measurable cycle time gains without introducing risk.
Robot Cell Design begins with process mapping, not robot selection
Before deciding on robot reach, payload, or brand, the first step is to map the process in detail. What exactly is the robot doing, what is the machine doing, and what must the operator do between cycles? Where are the waits? Where do faults occur? Which steps are variable because parts arrive differently, or because upstream processes fluctuate?
A strong design phase typically defines:
- Target cycle time, takt, and throughput requirements
- Product mix today and likely future variants
- Part presentation method (fixtures, pallets, conveyors, bins, AMRs)
- Quality checks required and where they sit in the sequence
- Changeover expectations and quick-change tooling needs
- Interfaces to machines, sensors, and any EMS/MES systems
- Maintenance access, clearing routes, and safe intervention points
This is also the point where Premier Automation provides honest advice about whether a robot is the right answer for the whole process, or only for a specific bottleneck. Sometimes a small peripheral improvement can unlock far more than a complicated robot strategy.
Robot Cell Design: Layout choices that cut seconds safely
The physical layout of a cell is one of the biggest drivers of cycle time. Unnecessary robot travel, poor approach angles, and cramped maintenance clearances can add seconds to every cycle, while also increasing the risk of stoppages.
Key layout principles that reduce cycle time without compromising safety include:
Short, direct robot paths
Place pick and place points to minimise travel and avoid unnecessary re-orientation. A compact working envelope often improves speed and repeatability, provided access and guarding are still practical.
Good part presentation
Cycle time is often lost before the robot even moves. If parts are inconsistently presented, the robot slows down, re-tries, or waits. This is why fixtures, conveyors, pallet systems, and vision (where needed) must be designed as part of the overall system, not bolted on later.
Efficient machine interfaces
In machine tending, the handshake between robot and machine tool can either flow smoothly or introduce pauses. Premier Automation has extensive experience with machine tool interfaces and standard loading cells, including pallet loaded, conveyor fed, pallet conveyor fed, and AMR-loaded approaches. The right interface strategy reduces idle time and creates reliable recovery after minor stops.
Safe access for operators and maintenance
A cell that is hard to access will be stopped more often, for longer. Designing safe clearing routes, sensible guarding, and logical access doors can reduce intervention time dramatically. Faster recovery is a major part of “cycle time” in the real world.
We also manufacture tooling and fabrications in-house, including robot pedestals, support frames, guarding, and spreader plates. That helps keep the design practical, cost-effective, and quicker to deliver.
Robot Cell Design: Controls and safety that support uptime
Even the best mechanical layout will underperform if the controls are not designed for production reality. The control system should make the cell easy to run, easy to diagnose, and quick to recover. That is why Premier Automation designs and manufactures control systems for robots, special purpose machinery, and process lines, with an emphasis on intuitive interfaces.
As a Siemens Solution Partner, we build controls to a high standard and deliver the documentation that supports safe, maintainable systems. Design is executed in the latest Eplan platform and can include full schematics, parts lists, panel layouts, cable schedules, EN13849 safety reports, and controls risk assessments. Panels are built in-house by qualified electricians and fully tested prior to despatch.
From a cycle time perspective, the biggest control-system wins often come from:
- Reducing nuisance trips through correct safety architecture
- Clear alarm messages that guide operators to the quickest recovery step
- Stable sensor selection and robust wiring practices
- Consistent sequence logic and deterministic handshakes
- Data and diagnostics that identify repeat causes of minor stops
Safety and performance are not opposites. When safety is engineered properly, it supports faster recovery, fewer stoppages, and more predictable running.
Programming, simulation and proving before you stop the line
Commissioning time is where many projects lose momentum. If programming only begins when equipment arrives on site, you are forced into long stoppages and rushed changes. Premier Automation uses off-line programming and simulation tools such as Robot Studio and Siemens PLC Sim to build and edit programmes away from production, creating a digital twin when appropriate.
This approach helps you:
- Optimise robot paths and sequence timing before installation
- Validate safety behaviour and interlocks in a controlled environment
- Reduce on-site commissioning time and disruption
- Make programme updates to existing cells without shutting down production for long periods
For upgrades and re-engineering, this is particularly valuable. A working cell can be re-programmed and improved while production continues, then implemented during a planned window.
Where Premier Automation fits
Founded in 2000, Premier Automation has developed into one of the UK’s leading suppliers of robot-based automation and control systems, operating from a large facility in Bedford with strong transport links nationwide. We integrate a wide range of robot models across applications such as machine tending, palletising, welding, and dispensing, and we hold ABB Value Provider status.
If your target is shorter cycle times without compromising safety, Robot Cell Design should be treated as an engineering system, not a collection of parts. Whether you need a new cell, an upgrade to an existing installation, or a relocation with performance improvements built in, Premier Automation can assess your process, define the right solution, and deliver a robust, reliable cell that performs safely on the shopfloor.
