The Role of Process Development in Automation Presentation
The Role of ProcessDevelopment in Automation Tom Lawton President ADVENT DESIGN CORP.
Process Development What is process development?The sequence of operationsand parameters required foreach operation to ensure thatthe manufacturing processproduces a product withinspecifications. Define transformation requirements of each step of the manufacturing process Define the sequence of steps
Automation Will Change your Process Why does the manufacturing process change?Tools used totransform the productwill changeSequence of stepsmay changeAbsence of HumanElement Intellect Dexterity Adaptability
Identify Your ProcessUnderstand what’schangingQuantify ParametersRepeatabilityEvaluate manualprocesses carefullyQuality RequirementsEnvironmental EffectsBe willing to makeproduct design changes You will miss things during the identification process.
Qualify and Test Process Changes Manufacturing Process Changes Product Design ChangesWherever possible integrate process changesinto the existing manufacturing process firstEvery process change has unanticipatedconsequencesUnderstand the consequences before cuttingmetal
Minimize RiskThe more you change your product or processthe higher the riskThe more processes you link together the greateryour down time 99.910 = 99% @ 100 parts/minute = down every minute
Common PitfallsUnderestimate the human elementIncoming parts not within specificationDevelopment components not trulyrepresentative of production componentsProcess is not repeatableProduct Design changes
Machine DesignSelect a transport system based on the requirements of the process.
RobotAdvantages Disadvantages Programmability Sequential steps increase cycle time Easy to link processes Limits to part gripping with different cycle because of single end- times effector Ability to change changing end-effector operation further increases cycle time Based on sensor inputs
Rotary (Dial Table)Advantages Disadvantages Low Cost Size Limitations - Fast large parts & high Accurate number of stations requires a large dial Size limits number of operations and Poor operator access associated risk Difficult to maintain
Synchronous InlineAdvantages Disadvantages Mid-range cost Slightly slower than More flexibility with rotary part size and number of stations better work cell layout allows easy operator access
Asynchronous InlineAdvantages Disadvantages Best method when Very high cost when combining manual pallets required and automatic Slower than operations synchronous Allows accumulation between stations
Walking BeamAdvantages Disadvantages Very cost effective in Hard to use if pallet no pallet required required Enables different part fixturing in each station
Machine Design for Process Development Do Dontuse PLC or other combine operations ifprogrammable at all possiblecontroller - Linking operationsoversize PLC limits flexibilityuse Op Interface because if effects the other processesinclude extra stations use mechanical camsuse sensors - when in or linkagesdoubt include asensor
Machine Design for Process Development (Cont.) Do Dontuse pneumatic directly connectactuators where electrical sensors orpossible actuators - go throughuse servo actuators PLCwhen you need tocontrol motionuse flexible framing(Bosch or other)use off the shelfsubsystems whenpossible
In SummaryUnderstand your process thoroughlyDon’t underestimate the human eliminateTest manufacturing process and productdesign changesMinimize riskDesign to monitor and adjust processparameters