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:
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.
Some common goals might be to:
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.
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:
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:
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.
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.
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:
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.
You should know your goals concerning:
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.
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.