So, You Want to Automate?

Summary

Automation has gripped the world unlike ever before. Prior to the onset of COVID, we were well on our way to automating the world, but the pandemic greatly accelerated that transformation. Today, we see manufacturers all over the world sprinting to automate their factories and facilities, but how does one start? There is so much to consider that the entire process can be quite overwhelming. Here are a few tips to get you moving in the right direction.

Start small

If you are new to the idea of automation and are looking to test the waters, start small. Examine your processes and think about future state. What processes can you automate to free up your employees so they can work on more complex tasks? Make a list and weigh the options. Analyzing front end costs vs. future cost savings from streamlined processes and reduced man hours spent will help you identify specific tasks that may be good options for automation.

Predictive maintenance and condition monitoring are some of the easiest and fastest ways to dip your toes into the pool of automation. Predictive maintenance uses data-driven, proactive techniques to estimate when maintenance should be performed, lowering expenses by eliminating unnecessary time-based repairs. Predictive maintenance is enabled by condition monitoring, which assesses the current state of a system by measuring specific machinery parameters like vibration and temperature to identify changes that may signify the need for corrective action.

If you prefer to start with robots, there are robot leasing services known as Robots-as-a-Service that will allow you to add robotics to your processes at a fraction of the cost of buying them outright. Services like these will usually include warranties, tech support and servicing. In many cases, they will also help tailor the robots to fit your needs, whether you are looking to add COBOTs or autonomous mobile robots (AMRs) to your facility.

Partner with an expert

Maybe you’re not savvy when it comes to all things automation. Afterall, you don’t know what you don’t know. In this case, consider talking with a systems integrator, who can walk you through the entire automation process. A systems integrator will evaluate your processes and provide ideas on what and how to automate. They will work with you on a design concept and provide you with an analysis on future cost savings and production improvements. Once you have chosen the path you want to take with the integrator, they will build the automation system, install it, test it, commission it and take you to the finish line.

Not all systems integrators are the same, though, so it’s important to do your homework. Each integrator specializes in different aspects of automation, such as products, systems, and even markets like food and beverage, water and wastewater management, etc. Integrators also provide different levels of support and services. Aggregators and many other online resources will enable you to research systems integrators to find the right one for your application.

Be sure to consider intellectual property and documentation when contracting with a systems integrator. Your integrator will move on to another customer once they complete your project, and they may choose to use lessons learned or even designs from your project in future designs. In most cases this isn’t a big deal, but you may not want a competitor to have access to your build and secret sauce, so to speak. This is a conversation you must have up front with your integrator. If there are any non-disclosure agreements to sign, this is a good time to work those out. Documentation should also be discussed, as establishing a safe, centralized location for all documentation related to the build is important. This will save you time and headaches later.
 

Plan for growth

Make your new, automated system scalable. This will allow you to add to your system in the future and enable the existing and new elements to communicate and work together as one. Otherwise, you risk having to scrap the original automated system and install a new one that handles both the old and new processes.  Whether you are installing a robot, material transport, an AMR, or simply predictive maintenance, all aspects in the automated system should work together.

Automating facilities can be a daunting task for anyone, whether you have been in automation for years or are starting out new. Fortunately, there are a great number of resources out there to help you, no matter where your factory or facility might be in the automation journey. From robot services to systems integrators and beyond, automation options continue to develop and expand, empowering customers to become more efficient and productive, more competitive, and even more successful in their business.