The Role of ProcessDevelopment in Automation

The Role of ProcessDevelopment in Automation

Tom LawtonTom LawtonPresidentPresident

ADVENT DESIGN CORP.ADVENT DESIGN CORP.

Process DevelopmentWhat is process development?

Process DevelopmentWhat is process development?

Define transformationDefine transformationrequirements of eachrequirements of eachstep of thestep of themanufacturingmanufacturingprocessprocessDefine the sequenceDefine the sequenceof stepsof steps

The sequence of operationsThe sequence of operationsand parameters required forand parameters required foreach operation to ensure thateach operation to ensure thatthe manufacturing processthe manufacturing processproduces a product withinproduces a product withinspecifications.specifications.

Automation Will Change your ProcessWhy does the manufacturing process change?

Automation Will Change your ProcessWhy does the manufacturing process change?

Tools used toTools used totransform the producttransform the productwill changewill changeSequence of stepsSequence of stepsmay changemay changeAbsence of HumanAbsence of HumanElementElement

IntellectIntellectDexterityDexterityAdaptabilityAdaptability

Identify Your ProcessIdentify Your Process

Understand what’sUnderstand what’schangingchangingQuantify ParametersQuantify ParametersRepeatabilityRepeatabilityEvaluate manualEvaluate manualprocesses carefullyprocesses carefullyQuality RequirementsQuality RequirementsEnvironmental EffectsEnvironmental EffectsBe willing to makeBe willing to makeproduct design changesproduct design changes

You will miss things during the identification process.

Qualify and Test Process ChangesQualify and Test Process Changes

Manufacturing Process ChangesManufacturing Process ChangesProduct Design ChangesProduct Design Changes

Wherever possible integrate process changesWherever possible integrate process changesinto the existing manufacturing process firstinto the existing manufacturing process firstEvery process change has unanticipatedEvery process change has unanticipatedconsequencesconsequencesUnderstand the consequences before cuttingUnderstand the consequences before cuttingmetalmetal

Minimize RiskMinimize Risk

The more you change your product or processThe more you change your product or processthe higher the riskthe higher the riskThe more processes you link together the greaterThe more processes you link together the greateryour down timeyour down time

@ 100 parts/minute = down every minute

99.910 = 99%

Common PitfallsCommon Pitfalls

Underestimate the human elementUnderestimate the human element

Incoming parts not within specificationIncoming parts not within specification

Development components not trulyDevelopment components not trulyrepresentative of production componentsrepresentative of production components

Process is not repeatableProcess is not repeatable

Product Design changesProduct Design changes

Machine DesignMachine DesignSelect a transport system based on theSelect a transport system based on the

requirements of the process.requirements of the process.

RobotRobot

AdvantagesAdvantagesProgrammabilityProgrammability

Easy to link processesEasy to link processeswith different cyclewith different cycletimestimesAbility to changeAbility to changeoperationoperation

Based on sensorBased on sensorinputsinputs

DisadvantagesDisadvantagesSequential stepsSequential stepsincrease cycle timeincrease cycle time

Limits to part grippingLimits to part grippingbecause of single end-because of single end-effectoreffector

changing end-changing end-effectoreffectorfurther increasesfurther increasescycle timecycle time

Rotary (Dial Table)Rotary (Dial Table)

AdvantagesAdvantagesLow CostLow CostFastFastAccurateAccurateSize limits number ofSize limits number ofoperations andoperations andassociated riskassociated risk

DisadvantagesDisadvantagesSize Limitations -Size Limitations -large parts & highlarge parts & highnumber of stationsnumber of stationsrequires a large dialrequires a large dialPoor operator accessPoor operator accessDifficult to maintainDifficult to maintain

Synchronous InlineSynchronous Inline

AdvantagesAdvantagesMid-range costMid-range costMore flexibility withMore flexibility withpart size and numberpart size and numberof stationsof stationsbetter work cell layoutbetter work cell layoutallows easy operatorallows easy operatoraccessaccess

DisadvantagesDisadvantagesSlightly slower thanSlightly slower thanrotaryrotary

Asynchronous InlineAsynchronous Inline

AdvantagesAdvantagesBest method whenBest method whencombining manualcombining manualand automaticand automaticoperationsoperationsAllows accumulationAllows accumulationbetween stationsbetween stations

DisadvantagesDisadvantagesVery high cost whenVery high cost whenpallets requiredpallets required

Slower thanSlower thansynchronoussynchronous

Walking BeamWalking Beam

AdvantagesAdvantagesVery cost effective inVery cost effective inno pallet requiredno pallet requiredEnables different partEnables different partfixturing fixturing in eachin eachstationstation

DisadvantagesDisadvantagesHard to use if palletHard to use if palletrequiredrequired

Machine Design for ProcessDevelopment

Machine Design for ProcessDevelopment

DoDouse PLC or otheruse PLC or otherprogrammableprogrammablecontrollercontrolleroversize PLCoversize PLCuse Op Interfaceuse Op Interfaceinclude extra stationsinclude extra stationsuse sensors - when inuse sensors - when indoubt include adoubt include asensorsensor

Don'tDon'tcombine operations ifcombine operations ifat all possibleat all possible- Linking operations- Linking operationslimits flexibilitylimits flexibilitybecause if effects thebecause if effects theother processesother processesuse mechanical camsuse mechanical camsor linkagesor linkages

Machine Design for ProcessDevelopment (Cont.)

Machine Design for ProcessDevelopment (Cont.)

DoDouse pneumaticuse pneumaticactuators whereactuators wherepossiblepossibleuse servo actuatorsuse servo actuatorswhen you need towhen you need tocontrol motioncontrol motionuse flexible framinguse flexible framing((BoschBosch or other) or other)use off the shelfuse off the shelfsubsystems whensubsystems whenpossiblepossible

Don'tDon'tdirectly connectdirectly connectelectrical sensors orelectrical sensors oractuators - go throughactuators - go throughPLCPLC

In SummaryIn Summary

Understand your process thoroughlyUnderstand your process thoroughlyDon’t underestimate the human eliminateDon’t underestimate the human eliminateTest manufacturing process and productTest manufacturing process and productdesign changesdesign changesMinimize riskMinimize riskDesign to monitor and adjust processDesign to monitor and adjust processparametersparameters