Manual transfers determine cycle time
Map operation times, waiting times and bottlenecks to identify actions suited to automation.
01 / SOLUTIONS
Start with the process.
Find the right solution.
Explore applications, system modules and implementation boundaries—from manual transfers and dedicated machining to connected equipment.
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01 / FIND YOUR SOLUTION
Start with your challenge.
Find a way forward.
Choose a discipline to explore its applications, processes and configurations.
01 / CUSTOM AUTOMATION
Connect separate actions into a continuous process.
Start with a repetitive task. Map loading, positioning, execution and inspection, then assess the right scope for a standalone machine or connected stations.
- Repetitive loading and manual transfers
- Multi-station assembly and coordination
- Mixed-product production and changeover
Start with these questions01 02 03
Assembly depends on operator experience
Separate positioning, error-proofing, execution conditions and inspection decisions to define what triggers each action.
Product changes limit equipment reuse
Distinguish fixed structures from interchangeable parts and discuss fixtures, recipes and changeover early.
What could your solution include?
Modules are combined around project requirements.
Loading & Positioning
Evaluate operator assistance, trays or dedicated feeders against part orientation, surface requirements and incoming material presentation.
Execution & Transfer
Design assembly actions, station timing and transfer methods together, accounting for interference, accessibility and maintenance space.
Inspection & Error-proofing
Define checks for missing parts, incorrect assembly, positioning and key process states, with clear responses to faults.
Operation & Changeover
Define manual, automatic and setup modes, including recipe selection, fixture changes and fault recovery.
PROCESS EXAMPLE
How a typical process connects
- 01Part preparation
- 02Position check
- 03Process execution
- 04Process check
- 05Unload & sort
Automation level, station count, changeover and inspection are assessed against samples and processes. This example is not a fixed product configuration.
What should you prepare?
- Part information
- Drawings, samples, incoming orientation and permitted contact areas
- Process needs
- Assembly sequence, decision criteria, target cycle time and shifts
- Site conditions
- Layout space, upstream/downstream interfaces, air and power supplies, and operator responsibilities
02 / PRECISION MACHINING
Align workholding, machining and inspection to one datum.
Use part features and the machining route to discuss datums, workholding, operation sequence and handling, then define the problem dedicated equipment must solve.
- Dedicated operations and batch production
- Repeated clamping and datum changes
- Coordinated machining-cell handling
Start with these questions01 02 03
Repeated clamping causes process variation
Review datum changes, clamping directions and contact points, and define how to verify positioning repeatability.
Auxiliary actions consume production time
Analyze handling, cleaning, tool changes and inspection separately to identify actions that can run in parallel or off-machine.
Changeover and maintenance interrupt production
Review fixture interfaces, access to wear parts, chip removal and cleaning space with daily maintenance in mind.
What could your solution include?
Modules are combined around project requirements.
Locating & Clamping
Select datums and clamping methods based on material, geometry and cutting forces—not clamping force alone.
Machining Mechanism
Assess motion, travel and tool clearance against process needs, checking rigidity, interference and machining access.
Workpiece Handling
Consider loading orientation, surface protection, process coordination and chips, with clear boundaries between operator and machine tasks.
Process & Output Checks
Distinguish machine-state checks from part measurement. Agree measurement methods and acceptance samples against the drawing.
PROCESS EXAMPLE
How a typical process connects
- 01Datum check
- 02Locate & clamp
- 03Dedicated machining
- 04Part inspection
- 05Unload & clean
Accuracy, cycle time and size range depend on the part, process and inspection conditions. They cannot be inferred from concept images.
What should you prepare?
- Part definition
- Drawing revision, material, blank condition and critical machined surfaces
- Assessment criteria
- Tolerances, surface requirements, inspection methods and acceptance samples
- Production conditions
- Target output, changeover frequency, existing processes and auxiliary operation times
03 / SMART INTEGRATION
Connect machine actions, states and data.
Review existing equipment and interfaces, then define sequences, signal meanings and data uses to connect status acquisition with fault response.
- Standalone and multi-machine control
- Machine-status visualization
- Process records and traceability
Start with these questions01 02 03
Machines lack clear handshakes
Agree start, complete, entry-permission and fault signals so upstream and downstream systems interpret states consistently.
Alarms do not identify the cause
Organize alarms by action conditions, identifying the source, impact, acknowledgement and recovery requirements.
Collected data cannot be linked to parts
Define why data is recorded before linking part IDs, timestamps, operations and results.
What could your solution include?
Modules are combined around project requirements.
Field Sensing
Identify required states and measurements, then check signal sources, update rates and acquisition conditions.
Action Control
Define modes, sequences, interlocks and fault branches, including conditions for resuming or re-homing after a stop.
Operator Interface
Organize machine overviews, process states, parameters and alarms so operators can identify the next action.
Data Interfaces
Define fields, read/write directions, recording rates and disconnect handling, with agreed boundaries for existing systems.
PROCESS EXAMPLE
How a typical process connects
- 01Acquire signals
- 02Evaluate states
- 03Coordinate actions
- 04Record results
- 05Report exceptions
Communication methods, control platforms and data scope depend on an on-site interface review. Retrofitting existing equipment requires a separate feasibility assessment.
What should you prepare?
- Existing equipment
- Equipment list, control systems, existing interfaces and available documentation
- Coordination needs
- Action sequences, signal list, mode switching and exception-handling rules
- Data uses
- Recorded fields, part-linking method, retention scope and supervisory-system interfaces
02 / PROJECT DELIVERABLES
Define each stage.
Agree its deliverables.
Agree scope and deliverables before the project starts to guide reviews, manufacturing and acceptance.
Align the objectives
Requirements & Concept
- Process requirements and constraints
- Equipment layout and process proposals
- Key risks and items to validate
Develop the concept into a design
Design & Manufacturing
- Mechanical and control design scope
- Interfaces, component selection and parts list
- Manufacturing and assembly checks
Verify agreed operating conditions
Validation & Delivery
- Commissioning records and issue resolution
- Operation and maintenance documentation scope
- Acceptance checks and site coordination
This is a framework for discussing delivery scope. Documents, training and on-site support are subject to the project agreement.
03 / BEFORE WE START
Before we start.
01Can we start without complete drawings?
Yes. Part photographs, current operations, improvement goals and target output can support an initial discussion. Drawings or samples will still be needed for structural, machining and inspection assessments.
02Should we automate one machine or a whole line?
Begin with bottlenecks, upstream/downstream cycle times and product-change frequency. A developing process may suit phased implementation. Defined interfaces allow a closer assessment of connected stations.
03Can existing equipment be retained and integrated?
First review space, signals, control interfaces, documentation and retrofit restrictions. Then define what to retain, modify or add. Equipment names alone cannot establish integration scope.
04When can cost, cycle time and lead time be confirmed?
Parts, processes, configuration, acceptance conditions and delivery scope must first be defined. Cycle-time calculations should state whether loading, changeover and inspection are included.