We see increasing automation in industries from food, semiconductor, transportation, labs, and even construction. Companies challenged with remote resources and local labor needs are looking toward automation solutions to make up the difference.
Automation of Industrial Systems and Processes
We are working on systems where companies are breaking down complex operations and automating the repetitive time-consuming tasks. The systems promise a strategic competitive advantage by significantly reducing labor requirements. Done well automation can add advantages in material management and greater output consistency.
How to Develop Machines to Replace Manual Processes
Research Requirements
The first step is to research the requirements. In most operations there will be many interrelated tasks carried out in particular sequences with decisions being made throughout. A time study of the potential automation opportunities along with an understanding of the current associated labor components is one way to narrow down the ROI candidates. Often a few areas stand out. They are typically repetitive and simplistic in nature. The more complex tasks with multiple user tools / decisions are often not the initial favorites since they are much more difficult to develop and maintain. Some key questions to ask yourself in this research effort are:
What is the reason for the change? Automation for automations sake is not good.
Is automation needed for labor reduction and/or quality enhancement?
What is the ROI required to make this change? These projects may not make sense financially, so be careful how they are justified.
What tasks are needed? Is the current process well documented for operational steps as well as quality compliance monitoring?
Are the materials that flow through the process consistent and appropriately designed for automation. Have they been developed with automation in mind or is it an afterthought?
How does the data gathered relate to associated processes?
What subsystems are required?
What is the typical flow of material/information?
How are errors or outliers handled?
What are the risks (hazardous materials / processes, component availability over the long term, maintenance difficulties, others)?
System requirements documentation availability? Have the performance requirements been defined and clearly communicated in commonly available documentation? Is there a machine spec or a Product Requirements Document (PRD)?
Research Existing Solutions
Second, looking at the marketplace, what equipment or subsystems are available? It may not be necessary to build new equipment if acceptable systems are commercially available. Even subsets of the overall design can be helpful. In many cases we have developed transfer system that take materials from process to process using robotics systems. The output of one process step is fed it to the input of the following process step. In these cases the ROI comes from the creation a very efficient overall operation that can run lights out for as long as needed. It can also group unique machines into an overall manufacturing process that meets quality and throughput requirements.
Evaluation and Integration
Even if you cannot find the complete solution in the marketplace, you can leverage existing subsystems in different ways. For example, there may be a number of inspection systems that can be adapted or grouped to meet your needs. Which will be best suited for your overall system requirements, and how will they interact with the rest of the flow? You can normally rely on the current inputs and outputs from your manual process as clear requirements for a replacement system. We promote a phased development approach that may semi automate some of the tasks initially. This allows the ROI to start sooner while you tune the overall process of a fully automatic solution.
Key questions to ask yourself are:
If you are pursuing subsystem integration
Is each subsystem a proven solution?
Available for the life of the system?
Well supported?
Easy to use and integrate?
Does the end customer for the automation system have the staff related skillsets to both operate and maintain the system? Many believe that automation is a panacea for their problems without considering the related infrastructure required for its use.
Do you have the development resources and schedule available to accomplish program success?
Experienced Personnel
Program Management
Mechanical Engineering
Electrical Engineering
Automation programmer
Component vendor connections
Fabrication vendor connections
Build, Test, and Implement
With this understanding of the needs and the gaps in solutions, it is possible to begin the build, test and implement phase. With the scope of the new system defined, you can appoint the project team, they can prepare a project plan, define testing/approval procedures, and establish the roles and responsibilities of all team members. The plans can then be executed.
Deployment will include delivery of all equipment, software, and documentation as well as the customer’s acceptance of the delivery. Training may be needed with standard operating procedures, work instructions, and process descriptions. The system should be mature enough to be transferred from the project team to the operational team. Acceptance testing should include an operational period of performance appropriate for the process. The new system can be used in production, realizing the improved process.
An alternative, and often attractive approach is to develop a proof of concept that demonstrates operational aspects but does not yet have a hardened / fully compliant design yet. These systems come out of the process much faster and allow all to provide feedback before continuing.
Efficient processes are important in the current climate of competitive global markets, variable demand, and competitive pricing. Where processes heavily depend on the workforce, efficiency becomes even more critical. As a final note, there is no end point; optimizing business process efficiency will always be ongoing.
Punchlist of considerations:
Safety requirements (electrical, mechanical, earthquake, industry specific)
Ergonomics (loading, unloading, human handling, maintenance access / component swapping)
Maintenance documentation (team abilities, associated tools, rapid problem diagnosis, spare parts recommendations).
Factory acceptance criteria, process and location(s)
Consistency of materials that flow into and out of the process. Do the parts come in a format that is automation friendly or do they need to be kitted?
Intermediate process quality standards and measurement methods.
Consider the progressive approach. Develop and prove out portions of the overall project before integrating them. This allows proper performance subsystem development before integrating them together. Integration will have its own challenges. Why add those within each process to create overly complex debug activities?
Shipping
Packaging (design, assembly method, materials and associated resources)
Environmental aspects (during transport, materials disposal after transport)
Transport methods and limitations
Tear down and bring up assembly related tasks
Supporting documentation
Certifications and monitoring instrumentation during transport.
Maintenance and continuous improvement
Does the team have the skills to operate and improve performance? Make sure there is an in-house team that is there for daily support. Enhancements can be outsourced but must be fully documented in case support vendors need to be updated.
Look for wear points in the system and tune your service and spare part management to support them rapidly. A down machine is not making money.
Keep a performance tracking system active to see any deviation challenges before the system goes off line
Fusion can help with your industrial automation projects
Fusion Design is a top tier mechanical engineering and invention design company based in Silicon Valley. Since 1990, we have helped countless individuals and both small and large companies overcome their challenges on the journey from concept to creation.
