Careful Planning Required to Take Full Advantage of Automation

While robotics and automated processes can bring greater efficiency, lower costs and other perks, Vice President of engineering at Applied Manufacturing Technologies, Craig Salvalaggio says “Automation allows companies to use human workers for more value-added tasks” but warns “there are more stories about automation projects that were turned off than there are about successful automation projects.” These disappointments were due to poor planning and preparation, he notes.

“Should you decide to automate, you need to identify what the requirements are and understand the process and level of automation,” Salvalaggio said.

Technological advances with robotics and automation accessories, along with a drastic reduction in related expenses, are propelling the advance of automation, even in small manufacturing facilities. These developments are also allowing some manufacturing to be brought back to the US. Moving production of US-consumed products back to domestic ground also reduces transportation costs and can make room for higher overall margins.

“But not every process is good for automation,” Salvalaggio warns. “After running a deep analysis, you may find that automation may not be answer for your underlying problem. You need to consider the tooling, the equipment, and all of the other costs involved.” Reasons he says to consider automation are to reduce quality issues, provide a safer working environment, and decrease costs.

When considering an automation project, companies should be cognizant of the schedule, installation time, budget and ROI period.

If capital outlay is an issue, subscription-based programs based on usage may be an option. Known as RaaS, these programs are similar to equipment leases. Other areas that should be evaluated include the possibility for scalability and facility changes, such as the floorplan and power requirements.

If scaling production is a goal, check with suppliers to ensure they can provide enough raw materials for the production increase. “Transparency with suppliers is critical,” Salvalaggio points out. “You need to make them partners in the process.” Part of the supply chain planning also includes a contingency plan on dealing with delays or price adjustments.

Integrating a human and machine system tends to give the best results, suggests Salvalaggio. With humans monitoring the results of automation, there is a better balance between the system and business needs.

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