How can you select the right automation technology for a legacy manufacturing system?

In my experience -To automation most important thing is standardization of process - Elimination of non value add processes - evaluate what could be challenges to automate process - Product may need redesign to accommodate automation. - Now when selecting automation keep in mind 1. Volume growth able to cater 2. ROI - Fastest is better 3. adoption for Future growth, new feature , new product , Integration with ERP , Real time analytics

Start by assessing the current state of manufacturing to Identify the processes, equipment, and workflows that need automation and determine the level of integration required with legacy systems. Consider the benefits of Industry 4.0 technologies like smart manufacturing, predictive maintenance, and cloud computing for upgrading legacy systems. To upgrade legacy manufacturing for automation, focus on updating older equipment to align with automation plans and ensure compatibility with modern systems.

Begin by analyzing the components, strengths, weaknesses, and potential for modernization of the existing legacy software. Conduct a comprehensive assessment of the application's architecture, functionalities, and dependencies when implementing automation testing for legacy applications. Consider automation technologies that are compatible with legacy systems and can seamlessly integrate with the existing infrastructure. Explore the use of robotics, artificial intelligence (AI), and machine learning (ML) technologies to automate repetitive tasks, enhance decision-making processes, and improve overall efficiency. Robotics can be particularly beneficial for tasks such as material handling, assembly, and quality control.

Integration and compatibility is the key, especially for manufacturing systems with multiple automation technologies/makes. Having simple systems and open interface to integrate with available/potential to have technologies made it easy for flexibility and adaptability. Of course, not to ignore being very well secured, protected and compliant with national and international cybersecurity regulations.

Introducing automation into a workforce can indeed be challenging, as it often involves significant changes in processes, roles, and responsibilities. Implement effective change management strategies to address resistance and concerns among employees. Acknowledge their apprehensions, address misconceptions, and highlight the opportunities for growth, learning, and career advancement that automation can bring. Clearly define new roles, responsibilities, and expectations resulting from automation. Ensure that employees understand how their roles may evolve and provide support and guidance to help them adapt to new job requirements.

In my limited experience, the sustainability matters the most than plan & implementation..because of legacy deep rooted in people’s mindset.. swift in mindset play key role on this..

When we try to modernise our legacy mfg by automation, we need to keep the following things in mind: 1.Buy in of all stakeholders through deep and clear communication, to allay fear of job loss and tell benefits of automation. 2.Building up of enough stock to avoid business disruption during the step by step modernisation of the legacy system. 3.Training of the production people to adopt the new system. 4. Revamping of maintenance organisation with the capability to take care of new features added / new machines added which are step change from legacy systems. 5.Training of the maintenance people to trouble shoot the new modernised system quickly and efficiently. 6.Sharing of the improvements realised to motivate all the stake holders.

A deep understanding of current and viable technologies to acquire would be a great beginning. It is key to identify prework that needs to be done to even start thinking of having benefits from an automation strategy. This includes at least: -Floor Level Strategy. Machine and its electrical diagrams. Sensors, Motors, etc. -Controlling Strategy. PLCs -SCADA Strategy. Including HMI or better yet IoT -ERP. Automation that does not integrate production planning is more likely to fail. -Cybersecurity roadmaps From that understanding or GAP analysis of legacy manufacturing systems you can build a future state and a realistic roadmap including prework ahead BEFORE even promising automation benefits.

Introducing automation into your process can streamline tasks, improve efficiency, and reduce errors. Consider using software tools for repetitive tasks, implementing workflow automation platforms, or leveraging robotic process automation (RPA) for more complex processes. Evaluate your workflow to identify areas where automation can make the most impact and start gradually implementing automation solutions.