Considering manufacturing automation in your factory? Some questions you should ask yourself before getting started.

There are many reasons to implement automation systems into your manufacturing facility.  There are some processes that are ideal for automation, while others are more difficult or not well suited to automate.  Where should you start?  In general, the more common automated manufacturing solutions include:

• Machine tending automation – Using robots or automated systems to load and unload production machines, such as computer numerical control (CNC) machines
• Automated assembly systems – Using robots or automated systems to assemble products
• Automated inspection systems – Using automated systems to inspect products or parts for defects or deviations
• Automated end-of-line operations – Using automated systems to package, label, and/or palettize finished products for shipping

If you’re planning to purchase automation technology or robotics in your manufacturing or industrial facility, there are some questions you need to ask yourself. These questions will help you (1) determine if automation is right for you, and (2) define the parameters and requirements for your system, which can help an automation engineering firm design a custom solution for your business.

The questions are open-ended. Answers will depend on the specific needs of your company and your manufacturing environment. Sometimes, your answer to one question will affect your answers to other questions in the list.

What problem or challenge are you hoping to solve with manufacturing automation?

Some common goals might be to:

• Increase throughput
• Reduce labor costs
• Reallocate human resources
• Improve worker safety and eliminate work related injuries
• Improve product quality and consistency
• Remove human resources from dangerous work environments
• Perform tasks that humans cannot

Defining your objectives is the first step when considering automation solutions.  For example, if you are having issues hiring and maintaining labor, automation may be a good solution.  You likely have processes that can be automated, and others that are not ideal for automation.  Automation of the processes you can automate allows you to allocate your workforce to tasks that cannot be automated, reducing your need to hire.

Is the process or task for which you require a solution one that can be automated?

This is probably the most important question you need to consider, yet the most difficult to answer. There are process factors that can help identify the best candidates for automation, such as:

• High repetition rate (i.e. high-volume batch manufacturing)
• Minimal product variation
• Process uses consistent and predictable components
• Clear requirements for process success (i.e. measurable results)
• Suitable for machine processing
• Data acquisition & collection requirements

Not all manufacturing processes are well suited for automation. Specifically, industrial processes that use compliant non-rigid components, are highly variable, require tactile touch or human perception, run at low volume or have irregular demand make automation more difficult to achieve.  Some real-world examples:

• Flattening & stretching fabric onto compliant substrates (i.e. automotive seats & furniture)
• Assembling wire harnesses with pre-cut wire leads
• Medical device assemblies that use long lengths of compliant tubing
• Bespoke products “built-to-order”

Just because you can automate something doesn’t mean you should. If you have a repeatable process but with low throughput, or a highly variable process that requires significant closed loop feedback control, an automated solution might not be achievable or worth the expense.

Have you considered upstream and downstream processes to those you would like to automate?

A rule of thumb in manufacturing automation: Don’t let go of the product until the process is complete.  Once components are located and oriented for automation, complete as much of the process as possible before releasing orientation.  For example, if implementing assembly automation and the process immediately after assembly is inspection, implementation of a combined solution will provide an improved ROI to assembly alone.  Consider your complete process before defining your project scope.

What cost evaluation will you use to justify the expense of automation? 

You have set your goals, and you believe your process can be automated, but how much can you spend?  Most automation systems are evaluated for return on investment.  There are several factors that are commonly considered when evaluating ROI on in automation investment, such as:

• Reduced labor costs
• Increased throughput capabilities
• Reduced training and human resources costs
• Improved worker safety & worker’s compensation cost reductions

What are your goals regarding Return on Investment (ROI) for automation?

Most companies expect manufacturing automation to produce an ROI within two years. It’s notable that the more you use automation, the faster you will achieve your ROI.

If, say, you have six manufacturing locations running three shifts, all using the same industrial automation system, you will achieve your ROI much faster than if you have only one manufacturing location running one single shift.

How do you know what to ask for or specify when investigating automation systems?

You should know your goals concerning:

• How many product types or part families will the automation need to handle
• What are your annual through-put requirements, now and for the next several years
• What are your quality and inspection requirements
• How will parts be presented to the automation cell for processing
• What do you want the automation system to do with parts that have completed the process
• What are your facility requirements needed to support an automation system (floorspace, power, air, water, etc.)
• What are your software and data acquisition requirements
• What is the implementation time of the automation system, and how will that affect your current manufacturing process

When implementing manufacturing automation, what does success look like?

Setting realistic expectations with automation is critical to success.  While it is tempting to establish requirements that align with ultimate performance and world-class manufacturing processes, it is rare to achieve such performance on initial delivery of a custom system.  It often takes several months of running an automation system to discover and solve problems.  Requesting this level of performance at delivery generally has significant impact on price while providing diminishing returns.  Consider what you require to be successful and set realistic expectations for machine acceptance.

Do you have the resources to run and support manufacturing automation? 

An aspect of automation that is too often overlooked is the support and maintenance requirements of a custom automation solution.  It is critical for companies to have the proper staff and skills in place to support and maintain an automation solution.  While the automation engineering firm that delivers the solution will be a key resource for service and support, having the capability to handle minor issues and basic maintenance in-house is an important aspect of automation system success.