How To Avoid Miscues With Your Assembly Automation Project

Fully Defined Scope and Deliverables

Clearly, it all starts with setting a common understanding of requirements and expectations.? However, it is important to remember that both the client and the automation partner have unique domain knowledge that needs to be shared and incorporated into the Statement of Work. Failure to fully define the scope and scale of the project can adversely affect the ROI of the project. Quality issues, ramp-up delays, and below-target through-put will jeopardize the project.

Client Responsibility: The client understands the product details, end-customer use cases, the intended assembly process, and key milestones.? If the product is currently being assembled manually, they will know whether there are any assembly steps that are difficult or problems that need to be addressed. The client may also be aware of changes to the product, components, materials, or potential variants that are in development. A clear definition of expected in-scope operations, functions, processes, product features, and product variants. All of these items should be brought to the table for discussion as they may affect the automation solution.

Automation Partner / Machine Builder Responsibility: A clear definition of delivered in-scope operations, functions, processes, product features, and product variants. The machine builder can draw on prior experience with similar or analogous projects.? This means that they can anticipate potential problems with components, assembly steps, or processes.? A good automation partner should be able to offer suggestions for improvements, changes, or substitutions.? They should be able to suggest an alternative assembly sequence, alternative processes (e.g. laser welding instead of screw/rivet assembly), and the optimal assembly method for maximizing the client’s ROI.?

Detailed Simulation

How can it be assured the machine will produce the target output??

The automation concept should be supported by detailed analysis, simulated operation, and validated performance.?

Supporting information to include:

• Subsystems must be represented and incorporate cycle times for individual axes and processes
• Control system execution time is confirmed
• Collision avoidance is confirmed
• Real-life cycle times validated from physical tests and/or prior projects
• Cycle times and coordination of subsystems with overall material handling system must be confirmed
• Utilization of a “Digital Twin” ensures fidelity between digital performance and physical performance

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Technical Experience & Operational Robustness

Aside from project CapEx cost, ROI is based on meeting a target date when the full through-put will be realized and assumed revenue recognition begins. An automation concept which uses a monolithic machine with custom subsystems in a custom architecture can create significant challenges with realizing performance targets, commissioning, ramp-up, maintenance, and future adaptability to new product variants.? Instead, use a modular and scalable design whenever possible.

?Why is a modular design preferred?

• The mechanical performance of modules and modular subsystems have likely already been validated multiple times in prior projects
• The base operating software is not written from scratch.? This reduces development time and debugging activities
• The base mechanical and electrical designs of modules and subsystems are already completed. Similarly, this reduces design time and testing activities
• Many important long-lead items are used across multiple projects and are likely in stock, or purchased in volumes to reduce costs
• Modular designs can be scalable.? A scalable system can be updated as the target production rate changes and the product’s features change.? A scalable system can be updated while maintaining the investment of the remaining machine modules.

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On-site Visits

• Automation Partner / Machine Builders Facility: Meet the entire team: design, assembly, quality, after-sales support, executive management. Have detailed discussion on how commissioning will be organized.? What are the expectations and logistics for machine run-off, training, and after-sales support personnel?
• Reference Customers / Track Record: The machine builder should have prior customers who are willing to show you their automation solutions/machines in operation.? The client should be free to have direct discussions with these prior customers.?
• Site of machine installation at client: There can be considerations which are not clearly illustrated in the SOW or site plans.? Locations of services, floor/wall/ceiling obstructions, and safety considerations are examples.

Financial Stability and Future Support

Is your automation partner going to be able to support you in one, three, five years??

This is an often-overlooked aspect of choosing an automation partner.? All industries have ups and downs.? Clients need to confirm that their machine builder has a robust financial condition which will weather a severe industry-wide downturn.? The automation partner might be needed in the future for machine maintenance, to upgrade the machine for a new product variant, or to train new employees. There are many recent stories where clients have found themselves in possession of a half-commissioned machine with an automation partner who is no longer able to finish the project.

DFM/DFA Services

Is your product ready for automation?

A new product in the design stage, or fresh from the design team is likely not fully optimized for manufacturing or assembly.? A good automation partner should have the capability to provide early-stage consulting services for DFM/DFA.? The benefits are many-fold: optimization of the material processes, component handling, assembly method, and packaging are critical for maximizing client ROI. Early stage DFM/DFA services can increase ROI by avoiding problems prior to mass production when changes are the costliest.

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Other Items…

There are certainly other items which can be included in the above list. However, the selected items attempt to highlight some of the primary issues to consider for the successful completion of an assembly automation project.

Contact me to discuss how STIWA Automation can support your current or future automation projects:

Brian St. Denis, P.E.

VP Business Development

STIWA Automation

803-984-2157

[email protected]