How to get started on an Automation Project Jason Fortune, Applied - - PowerPoint PPT Presentation

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How to get started on an Automation Project

Jason Fortune, Applied Manufacturing Technologies Advanced Engineer Solutions (AES) Group Leader

How to get started on an Automation Project?

How to get started on an Automatio ion Proje ject?

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.

Problem Statement:

$75,000.00 Coat Hanger!!

How to get started on an Automatio ion Proje ject? “Phase 0”:

1.Why Automate? 2.Where does Automation make sense in your process? 3.What level of Automation is appropriate for your facility? 4.How would Automation be accepted in your facility? 5.How much would Automation Cost? Is there a Business Case?

Should we Automate?

How much? How? What? Where? Why?

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Top Reason to Consider Automation

Increase Throughput Reduce Labor Cost Improve Quality Improve Safety Reduced Footprint

Top Business Requirement to Consider Before Automation

Schedule (Key Dates) Lead Time Capital Budget Limits Cost Payback Period (ROI)

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Top Reasons to Automate

Improve Throughput

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Top Reasons to Automate

Improve Throughput Reduce Labor Cost

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Top Reasons to Automate

Improve Throughput Reduce Labor Cost Improve Quality

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Top Reasons to Automate

Improve Throughput Reduce Labor Cost Improve Quality Improve Safety

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Top Reasons to Automate

Improve Throughput Reduce Labor Cost Improve Quality Improve Safety Reduced Footprint

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Bad Reasons to Automate

Tradeshow – Robots are Cool! The Competition is Automating Capital Budget Availability

Kuka, ABB, Universal Robotics, Baxter

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Why do Automation Projects Fail?

How to get started on an Automatio ion Proje ject?

Should we Automate? Why?

How much? How? What? Where? Why?

Results of Failed Automation

Safety Violations Final System Layout Process/Application Tracking Hardware Damage High Resource Utilization High Project Costs Recreation of Logic on Manufacturing Floor

How to get started on an Automatio ion Proje ject?

Should we Automate? Where?

How much? How? What? Where? Why?

Understanding Your Current Vs. Ideal Process

Current Ideal

How to get started on an Automatio ion Proje ject?

Should we Automate? Where?

How much? How? What? Where? Why?

Understanding Your Current Process

Value Stream Map Spaghetti Chart Process Flowchart

How to get started on an Automatio ion Proje ject?

Should we Automate? Where?

How much? How? What? Where? Why?

Understanding Your Current Process

Product Mix (How many?) Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly Number of Processes per Final Assembly

How to get started on an Automatio ion Proje ject?

Should we Automate? Where?

How much? How? What? Where? Why?

Understanding Your Current Process

Product Mix (How many?) Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly Number of Processes per Final Assembly Number of Operators Type of Equipment

How to get started on an Automatio ion Proje ject?

Should we Automate? Where?

How much? How? What? Where? Why?

Understanding Your Current Process

Product Mix (How many?) Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly Number of Processes per Final Assembly Number of Operators Type of Equipment Cycle Time

How to get started on an Automatio ion Proje ject?

Should we Automate? Where?

How much? How? What? Where? Why?

Understanding Your Current Process

Product Mix (How many?) Product Mix - How Many Final Assemblies? Number of Sub- Components per Final Assembly Number of Processes per Final Assembly Number of Operators Type of Equipment Cycle Time Current System or Line Throughput = Baseline Current Quality Numbers (Cpk, Ppk, Scrap, Rework) Footprint

How to get started on an Automatio ion Proje ject?

.

Should we Automate? What?

How much? How? What? Where? Why?

Determine the Appropriate Level of Automation

How to get started on an Automatio ion Proje ject?

Should we Automate? What?

How much? How? What? Where? Why?

Investigate Robots vs. Dedicated Machines

How to get started on an Automatio ion Proje ject?

Should we Automate? What?

How much? How? What? Where? Why?

Investigate Conveyors Vs. AGV’s

How to get started on an Automatio ion Proje ject?

Should we Automate? What?

How much? How? What? Where? Why?

Fully Automated Vs. Manual Inspections

How to get started on an Automatio ion Proje ject?

.

Should we Automate? How?

How much? How? What? Where? Why?

As Automation is introduced to your manufacturing process it is important to understand the impact that it will have on you current manufacturing environment.  Experience  Operation  Service & Maintenance  Tradesmen Qualifications  Safety (LOTO)  Etc.…

How to get started on an Automatio ion Proje ject?

.

Should we Automate? How Much?

How much? How? What? Where? Why?

How to get started on an Automatio ion Proje ject?

.

Should we Automate? How Much?

How much? How? What? Where? Why?

Considerations should be made for the Project schedule itself, but also to include all areas projected to be effected by the project itself. Staff Support Planning Commissioning Installation Operator Training Production Launch Production Interruptions

How to get started on an Automatio ion Proje ject?

.

Should we Automate? How Much?

How much? How? What? Where? Why?

All Stakeholders should agree on the Capital Budget Limits as Well as the ROI Requirements of the project in order to track project performance to Business expectations.

Budget vs. Capital Availability

Baseline

Reference – cogentys.com

Define Payback Time Define ALL Costs Establish you Baseline

Getting started on an Automation Project?

Phase 0 Initial Investigations 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

Advanced Manufacturing Engineering (AME) provides a structured process for manufacturing automation concept development from inception through procurement.

AME – Phase 1

Manufacturing Analysis is the point in the process where the trajectory is set for the entire project. Identify Stakeholders Set Targets Data Collection Preliminary Process Analysis Identify System Attributes

Phase 0 Initial Investigations 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

AME – Phase 1

Identify Stakeholders Can Impact Be Impacted Can Support MUST: Manage Control I = E(E – 1) 2

1 2 3

I = 3(3 – 1) 2 I=3

3

1 2 3 4 5

I = 5(5 – 1) 2 I=10

I = 10(10 – 1) 2 I=45

Phase 0 Initial Investigations 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

AME – Phase 1

Identify Stakeholders Set Targets Must have Quantifiable Targets to Work To Attempt to Quantify Relative Importance Engineers Focus on Process Requirements Targets NOT Set in Stone (Start Point!)

Phase 0 Initial Investigations 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

AME – Phase 1

Set Targets Workshop Create a Target List

Phase 0 Initial Investigations 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

AME – Phase 1

Identify Stakeholders Set Targets Data Collection Layout Process Descriptions Work instructions Production Numbers Product Styles Line Rates

Phase 0 Initial Investigations 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

AME – Phase 1

Identify Stakeholders Set Targets Data Collection Preliminary Process Analysis

Phase 0 Initial Investigations 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

AME – Phase 1

Identify Stakeholders Set Targets Data Collection Preliminary Process Analysis Identify System Attributes Scalability Flexibility Facility Changes Manufacturing Risk (POP) Technology Risk (POP) Etc.

Phase 0 Initial Investigations 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

Phase 0 Initial Investigations 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

AME – Phase 2

Concept Development is the when all project considerations are made to fulfill the Manufacturing Analysis requirements. Define Discrete Tasks Identify Multiple Solutions Per Task Conceptional Development Solution Generation Equipment Selection Pre-Engineering Pre Risk Evaluation & Proof of Principal Cost Analysis (ROM +/- 25%)

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Map the Process Station 1: Cut Part A Move Part A to Station 3 Station 2: Grind Part B Move Part B to Station 3 Station 3: Weld Part A to Part B

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Identify Multiple Solutions Per Task Cut Part A Manual With Saw Automated Robotic Waterjet CNC Laser Move Part A to Station 2 Manually Carry Conveyor Index Table

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Identify Multiple Solutions Per Task Conceptional Development

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Identify Multiple Solutions Per Task Conceptional Development Solution Generation

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Identify Multiple Solutions Per Task Conceptional Development Solution Generation Equipment Selection

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Identify Multiple Solutions Per Task Conceptional Development Solution Generation Equipment Selection Pre-Engineering Good, Better, Best

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Identify Multiple Solutions Per Task Conceptional Development Solution Generation Equipment Selection Pre-Engineering Pre Risk Evaluation & Proof of Principal

Phase 0 Initial Investigations 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

AME – Phase 2

Define Discrete Tasks Identify Multiple Solutions Per Task Conceptional Development Solution Generation Equipment Selection Pre-Engineering Pre Risk Evaluation & Proof of Principal Cost Analysis (ROM +/- 25%)

• System Cost $2,339,922
• 1 Area
• Baseline Cost $1,000,000
• $500,000 per Area
• 2 Areas
• Cost for Automation Business Case
• $1,339,922
• Additional Cost for Automation
• Cost to Eliminate 18 Operators

AME – Phase 3

Pre-Engineering and Specification Development is the when all project considerations are refined and documented within a Scope of Work for project execution. Pre-Engineering Risk Evaluation Proof of Concept Cost Analysis (ROM +/- 10%) Calibration of Business Case Creation of Functional Specification

Phase 0 Initial Investigations 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

Phase 0 Initial Investigations 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

AME – Phase 3

Pre-Engineering (Focused) Risk Evaluation (Focused) Proof of Concept (As Required) Cost Analysis (ROM +/- 10%) (Focused) Calibration of Business Case

Operators per Shift

Avg Wage Forming: 16.52 $ Benefits 37% OT 12% # Shifts 4 Single Operator Cost 51,233.15 $ Single Role Cost 204,932.58 $ Single Role 2 Year ROI Budget 409,865.16 $

# Operators / Shift # Shifts # Operators Cost / Operator / Year Cost / Year 2 Year Cost 10 4 40 51,233.15 $ 2,049,325.82 $ 4,098,651.65 $ Current Cost to Operate Lines 4 thru 8 ONLY

Estimated Automation Costs 2,848,094.00 $ Estimated Yearly Labor Savings 1,434,528.08 $ ROI Payback Estimate 1.99 ROI Payback Estimate: Single Project Estimated Automation Costs 3,209,598.09 $ Estimated Yearly Labor Savings 1,434,528.08 $ ROI Payback Estimate 2.24 ROI Payback Estimate: Phased Approach

AME – Phase 3

Phase 0 Initial Investigations 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

Pre-Engineering (Focused) Risk Evaluation (Focused) Proof of Concept (As Required) Cost Analysis (ROM +/- 10%) (Focused) Calibration of Business Case Creation of Functional Specification

System Specification

Target Settings

• Scope of Work
• Design Perimeters
• Intended Uses
• Sequence of

Operations

Design and Installation

Information for Use

• Pre Engineering
• Concept Specific

Documentation

• Risk Evaluation
• Proof of Concept

Control System

Information for Use

• Pre Engineering
• Concept Specific

Documentation

• Risk Evaluation
• Proof of Concept

System Operation

Information for Use

• Process Requirements
• Discrete Task

Requirements

• KPI’s
• CTQ Measurable

Customer Standards

Information for Use

• Corporate Standards
• Consensus Standards
• System Specific

Requirements

• T&C’s

Criteria for Selecting a Integrator

Integrator selections should include:

• 1. Integration Experience: Type and Size
• 2. Years in Business
• 3. What type of services do they provide.

4..

Process for Qualification and Selection of Integrator

Stake holders should completely review bids as submitted Compare SOW to Supplied Bids Clarify ALL differences and Bid Language Complete a Decision Analysis Process (Must’s, Needs, Wants) Interview Integrator Finalist (Scope, Cost, T&C, Risk) Integrator Site Audit Formal Review DA Information with Stakeholders Select Integrator

Evaluating Automation Bids: The Procurement DA Process

Management of the System Integrator

Project Management of a System integrator is KEY to Success

Project Kick Off – Identify and Reintroduce Execution Team and Project Stakeholders Establish a Project Communication Management Process Establish a Project Schedule (Include all Major Milestones and Stakeholder Interaction Points) Clearly Define Acceptance Criteria for ALL Milestones within the Project

Management of the System Integrator

Project Management of a System integrator is KEY to Success

Establish a Meeting Cadence that works for ALL Stakeholders Establish a Reporting Method for Progress Reporting Through the Project Establish a Tracking Method for Project Assigned tasks and Completion Follow Through Continually Manage the Project to SOW and Target Settings Execute the Acceptance Testing with Stakeholders and Note ALL Project Specific Alterations or Open Issues Prior to Project Closure Hold a Project Closure Meeting to Document all Lessons Learned Items Noted Throughout the Project Planning and Execution.

Management of the System Integrator

Project Management of a System integrator is KEY to Success

PMI-PMBOK Guide Fifth Addition

Thank you for your Time!

Jason Fortune

AES Team Leader

Applied Manufacturing Technologies 219 Kay Industrial Drive Orion, MI 48359 USA Phone: 810-397-8889 Email: Jfortune@appliedmfg.com www.appliedmfg.com