How to get started on an Automation Project Jason Fortune, Applied Manufacturing Technologies Advanced Engineer Solutions (AES) Group Leader PRESENTED BY
How to get started on an Automation Project?
Problem Statement: As technologies advance and production costs climb, automation continues to permeate new industries at a growing pace. While the net effect is positive, it seems that for every success story there is a project that failed. $75,000.00 Coat Hanger!! How to get started on an Automatio ion Proje ject?
Should we Automate? Why? “ Phase 0” : Where? 1.Why Automate? 2.Where does Automation make sense in your process? What? 3.What level of Automation is appropriate for your facility? 4.How would Automation be accepted in your facility? How? 5.How much would Automation Cost? Is there a Business Case? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Top Reason to Consider Automation Increase Throughput Where? Reduce Labor Cost Improve Quality Improve Safety What? Reduced Footprint Top Business Requirement to Consider Before Automation How? Schedule (Key Dates) Lead Time Capital Budget Limits How much? Cost Payback Period (ROI) How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Top Reasons to Automate Improve Throughput Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Top Reasons to Automate Improve Throughput Where? Reduce Labor Cost What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Top Reasons to Automate Improve Throughput Where? Reduce Labor Cost Improve Quality What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Top Reasons to Automate Improve Throughput Where? Reduce Labor Cost Improve Quality What? Improve Safety How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Top Reasons to Automate Improve Throughput Where? Reduce Labor Cost Improve Quality What? Improve Safety Reduced Footprint How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Bad Reasons to Automate Tradeshow – Robots are Cool! Where? The Competition is Automating Capital Budget Availability What? How? How much? How to get started on an Automatio ion Proje ject? Kuka, ABB, Universal Robotics, Baxter
Should we Automate? Why? Why? Why do Automation Projects Fail? Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Why? Why? Results of Failed Automation Safety Violations Where? Final System Layout Process/Application Tracking What? Hardware Damage High Resource Utilization High Project Costs How? Recreation of Logic on Manufacturing Floor How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Where? Why? Understanding Your Current Vs. Ideal Process Where? Current What? Ideal How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Where? Why? Understanding Your Current Process Where? Process Flowchart Value Stream Map Spaghetti Chart What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Where? Why? Understanding Your Current Process Product Mix (How many?) Where? Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly What? Number of Processes per Final Assembly How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Where? Why? Understanding Your Current Process Product Mix (How many?) Where? Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly What? Number of Processes per Final Assembly Number of Operators Type of Equipment How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Where? Why? Understanding Your Current Process Product Mix (How many?) Where? Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly What? Number of Processes per Final Assembly Number of Operators Type of Equipment How? Cycle Time How much? How to get started on an Automatio ion Proje ject?
Should we Automate? Where? Why? Understanding Your Current Process Product Mix (How many?) Where? Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly What? Number of Processes per Final Assembly Number of Operators Type of Equipment How? Cycle Time Current System or Line Throughput = Baseline How much? Current Quality Numbers (Cpk, Ppk, Scrap, Rework) Footprint How to get started on an Automatio ion Proje ject?
Should we Automate? What? Why? Determine the Appropriate Level of Automation . Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? What? Why? Investigate Robots vs. Dedicated Machines Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? What? Why? Investigate Conveyors Vs. AGV’s Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? What? Why? Fully Automated Vs. Manual Inspections Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? How? Why? As Automation is introduced to . your manufacturing process it is Where? important to understand the Experience impact that it will have on you Operation current manufacturing What? Service & Maintenance environment. Tradesmen Qualifications Safety (LOTO) How? Etc.… How much? How to get started on an Automatio ion Proje ject?
Should we Automate? How Much? Why? . Where? What? How? How much? How to get started on an Automatio ion Proje ject?
Should we Automate? How Much? Why? Considerations should be made . for the Project schedule itself, but Where? also to include all areas projected to be effected by the project itself. What? Staff Support Planning Commissioning How? Installation Operator Training Production Launch How much? Production Interruptions How to get started on an Automatio ion Proje ject?
Should we Automate? How Much? Why? All Stakeholders should agree on Budget vs. Capital Availability . the Capital Budget Limits as Well Where? as the ROI Requirements of the project in order to track project performance to Business What? expectations. Baseline How? Define Payback Time Define ALL Costs How much? Establish you Baseline How to get started on an Automatio ion Proje ject? Reference – cogentys.com
Getting started on an Automation Project? Phase 0 Advanced Manufacturing Engineering (AME) provides a Initial Investigations structured process for manufacturing automation concept Gate 1 Sniff Test development from inception through procurement. Phase 1 Manufacturing Analysis Gate 2 Concept Review Phase 2 Concept Development Gate 3 Design Review Phase 3 Pre-Engineering Specification Development Gate 4 AR Process
AME – Phase 1 Manufacturing Analysis is the point in the process where the Phase 0 Initial Investigations trajectory is set for the entire project. Gate 1 Sniff Test Identify Stakeholders Phase 1 Set Targets Manufacturing Analysis Data Collection Gate 2 Concept Preliminary Process Analysis Review Identify System Attributes Phase 2 Concept Development Gate 3 Design Review Phase 3 Pre-Engineering Specification Development Gate 4 AR Process
AME – Phase 1 Identify Stakeholders Phase 0 Initial Investigations Can Impact Gate 1 Be Impacted Sniff Test Can Support Phase 1 Manufacturing Analysis Gate 2 MUST: Concept Review Manage Phase 2 Control Concept Development Gate 3 Design Review 1 1 I = 3(3 – 1) I = 5(5 – 1) I = 10(10 – 1) 1 Phase 3 10 2 I = E(E – 1) 2 2 2 Pre-Engineering 9 3 I=3 5 2 I=10 I=45 Specification Development 3 2 8 4 3 2 Gate 4 AR Process 4 3 7 5 6
AME – Phase 1 Identify Stakeholders Phase 0 Initial Investigations Set Targets Gate 1 Must have Quantifiable Targets to Work To Sniff Test Attempt to Quantify Relative Importance Phase 1 Manufacturing Analysis Engineers Focus on Process Requirements Gate 2 Targets NOT Set in Stone (Start Point!) Concept Review Phase 2 Concept Development Gate 3 Design Review Phase 3 Pre-Engineering Specification Development Gate 4 AR Process
AME – Phase 1 Set Targets Workshop Phase 0 Initial Investigations Create a Target List Gate 1 Sniff Test Phase 1 Manufacturing Analysis Gate 2 Concept Review Phase 2 Concept Development Gate 3 Design Review Phase 3 Pre-Engineering Specification Development Gate 4 AR Process
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