Robot Programming Services for performance improvements
Most factories do not need “more automation” to improve performance. They need better utilisation of the automation they already have. Robot Programming Services are one of the fastest ways to unlock capacity, reduce downtime and improve quality without major capital investment. When programmes are optimised, sequences simplified and interfaces made more reliable, you can often achieve meaningful gains in throughput and consistency while reducing operator intervention and fault frequency.
Premier Automation, founded in 2000, is one of the UK’s leading suppliers of robot-based automation and control systems. We design and build new robot systems, integrate used robots, and modify or update existing automated systems to meet customers’ individual process requirements and payback criteria. Our experienced software engineers and programmers provide support across a wide range of installations, from single-cell robot systems to sophisticated automation systems incorporating multiple peripheral technologies. This article explains where performance is typically lost, what a professional optimisation approach looks like, and how programming changes can deliver measurable results.
Robot Programming Services: the most common performance drains
When a robot cell is underperforming, the cause is rarely a single issue. It is usually the combined effect of small inefficiencies that build up across each cycle, shift and week. A structured programming review looks at the cell as a complete system, not just robot motion.
Common performance drains include:
Excessive path length and unnecessary moves
Older programmes often accumulate “legacy” motion segments that are no longer needed. Removing them can reduce cycle time immediately.
Overly conservative speeds and accelerations
Speeds may have been set cautiously during early commissioning and never revisited. Optimisation can improve throughput without sacrificing safety or quality.
Inefficient handshakes with peripherals
Robots depend on signals from machines, conveyors, safety devices, vision systems and tooling. Slow or unreliable handshakes create waiting time and repeated stops.
Poor fault handling and recovery routines
If faults are not handled cleanly, operators reset the cell manually, increasing downtime and the risk of error. Better recovery logic improves uptime and confidence.
Inconsistent sequencing across product variants
High-mix environments often suffer when each product variant is programmed differently. Standardising routines reduces changeover time and errors.
Robot Programming Services focus on removing these losses systematically, then validating changes safely so improvements are reliable in production.
Robot Programming Services for cycle time reduction without compromising quality
Cycle time reduction is not simply increasing speed. It is improving the overall efficiency of the process while maintaining quality, repeatability and safe operation. The best results come from understanding the application, the tooling, and the upstream and downstream constraints.
Key methods include:
Motion optimisation and smoothing
Refining approach paths, blending moves appropriately, and ensuring the robot is not constantly stopping and starting unnecessarily.
Tool centre point (TCP) and frame verification
Poorly calibrated TCP or frames can lead to overcompensation in motion and inconsistent results, especially on dispensing, welding or precision placement.
Sequencing improvements
Restructuring tasks so the robot completes operations in the most efficient order, reducing non-productive travel.
Parallel operations where possible
In integrated cells, waiting for external events can be reduced by rethinking the order of checks, pre-positioning and preparation steps.
At Premier Automation, our engineers have experience in applications including machine tending, palletising, welding, and gluing and gasket dispensing. That breadth matters, because each application has different performance constraints and different quality risks.
Robot Programming Services using off-line programming and digital twins
Downtime is often the biggest barrier to improvement. Many manufacturers know their robot cells could be better, but cannot afford to stop production long enough to experiment. This is where off-line programming is powerful.
Robot Programming Services delivered off-line allow you to:
Create and edit programmes without shutting down production
Test new sequences and approaches before deployment
Validate cycle time changes with fewer surprises at installation
Reduce commissioning time and production disruption
Premier Automation uses tools such as RobotStudio and Siemens PLC simulation to create and edit programmes off-line. This approach supports faster implementation, especially when you are modifying a working cell or upgrading a line that must keep running.
In many cases, off-line work is combined with a short on-site window for final validation, fine tuning and sign-off.
Robot Programming Services on-site for upgrades, new products and recoveries
Not every change can be done entirely off-line. New products, new tooling, and altered machine interfaces often require on-site work to validate real-world conditions. On-site Robot Programming Services are commonly used when:
A product change requires new paths, pick points or process parameters
A throughput increase is needed quickly to meet demand
A cell has become unstable due to incremental modifications over time
A robot has been relocated and needs re-commissioning
A legacy system needs re-engineering to regain original performance levels
Premier Automation has experienced robot and PLC programmers available to visit customer sites and re-programme existing systems. We can work on robots integrated by other companies as well as our own systems, and we provide honest, unbiased advice on the most appropriate solution for your production problems.
Integration matters: PLCs, SCADA and the control system interface
Robot performance is often limited by the wider control system. Most automated systems incorporate a PLC to control peripheral aspects of the cell, communicate with external equipment, and interface with higher-level systems such as EMS or MES platforms. Programming improvements may involve:
Improving signal handshakes between robot and PLC
Optimising alarm handling and fault recovery logic
Enhancing HMI messaging so operators know what to do and why
Supporting data capture and traceability where required
Premier Automation is equally experienced in PLC programming with all major PLC types and can create full SCADA and custom MES systems from scratch. This means robot optimisation can be delivered as part of a complete cell performance improvement, not an isolated programme change.
What a typical performance improvement project looks like
A structured approach delivers better results than “tweaking until it seems faster”. A typical project will include:
- System assessment and baseline measurement
Cycle time, downtime reasons, fault frequency and quality impacts are reviewed. - Improvement plan aligned to commercial goals
Changes are prioritised based on payback, risk and operational impact. - Off-line development and testing where appropriate
Updates are built and validated to minimise on-site disruption. - On-site implementation, commissioning and training
Changes are proven in production conditions, and operators are trained on updated routines. - After-sales support
Ongoing assistance ensures improvements remain stable as production evolves.
Next steps
If you need higher throughput, fewer stoppages, or better flexibility from your existing automation, Robot Programming Services can be a cost-effective route to measurable gains. Premier Automation provides off-line and on-site robot and PLC programming, upgrades and re-engineering, supported by experienced mechanical and electrical engineers and a strong partner network.
To discuss performance improvements, contact Premier Automation and arrange a system assessment to identify where time is being lost and what changes will deliver the best payback.
