8 Ways to Plan Automation Projects without Disrupting Production
Totally integrated automation systems can bring great benefits to manufacturing businesses, but the installation of a new automated production line can disrupt or halt operations. However, with careful planning, adding production line automation can be achieved with minimal workflow interruption.
This blog will offer eight steps for installing automation projects without major production outages.
The Benefits of Automated Production Lines
Before delving into how to properly plan automation projects, understanding the benefits that make the automation journey worthwhile is essential.
Production line automation offers a number of efficiency- and profit-boosting advantages, including:
- Enhanced productivity: Automated production lines can operate continuously without breaks or fatigue, so the addition of automation or robotics allows manufacturers to operate for longer periods, significantly increasing productivity without adding to the workforce.
- Greater efficiency: Because automated equipment can move faster and more consistently than manual workers, bottlenecks and downtime will be reduced, boosting efficiency.
- Better product quality: Automated equipment, such as robots and cobots, are programmed for accuracy, precision and consistency, which means automated production lines can manufacture products with fewer errors than manual laborers because skills can vary between workers and fatigue can lead to mistakes. The addition of production line automation will likely result in better and more consistent product quality.
- Decreased waste: By eliminating human error, there will be less raw material waste and product being scrapped. Re-work will also be minimized. This will save money and help achieve sustainability goals.
- Improved safety records: Automation can be placed in hazardous areas of the facility or used to automate dangerous tasks, which will lower the risk of workplace accidents and injuries.
- Lower operating costs: Because the addition of automated production lines can help reduce scrap and waste and minimize downtime and injuries, while also increasing productivity and efficiency, operating costs will be reduced.
8 Steps for Installing Automated Production Lines without Production Outages
Because production line automation brings about a host of operational and financial benefits, many businesses are quick to begin automation projects without realizing that there are challenges involved – including the possibility of disrupting production during the installation process.
However, with thorough planning, transitioning to an automated production line can go off with minimal disruption to daily operations. Here’s how:
| Designate a team | Implementing an automation project usually involves in-house staff, as well as outside automation integrators. Experienced industrial automation integrators understand the design, engineering, installation and testing phases of rolling out automated production lines, but they will need the input of internal staff who have knowledge of plant operations and understand the full scope of the project. Creating a team of both internal experts and external automation integrators will ensure that both technical and operational goals are met. |
| Set clear objectives | When setting project objectives, define very specific operational goals for the project and be sure they align with the business plan. This should begin by analyzing the line being automated to identify bottlenecks, extra steps and where workflow improvements can be made. Be sure to develop achievable and measurable objectives. This is also a good time to discuss the anticipated timeline, schedule, budget, required resources and site prep work. |
| Create a comprehensive plan | Once goals are established, create a roadmap that includes every step of the automation project. Keep in mind that it is usually best to plan automation projects in phases, rather than automating an entire facility at once. Many manufacturers opt to slowly scale up automation so performance can be monitored and measured and any changes or adjustments can be made. This approach also minimizes total work stoppages. |
| Strategize timing | Because it is nearly impossible to continue operating normally during the installation of an automated production line, it is essential to time automation project installation, testing and deployment so they occur during slower production periods. Understand that even if the project is limited in scope or area, it will likely affect operation of the entire facility, so avoid projects during peak production times. |
| Be flexible | Although the goal is to maintain production during the installation and deployment of production line automation, it will require some flexibility as other areas of the plant will need to accommodate the transition. This may require using manual labor for previously automated tasks, moving workspaces or equipment and temporarily adjusting shifts during construction and installation. Keep in mind that shifting to manual operations will result in a loss of productivity, so account for this on the production schedule. Also, be sure the automation integrator is aware that they will need to work around existing processes and has the flexibility to do so. |
| Involve staff | Employee involvement is critical to success. Employees can be great resources during the planning stage as they can point out workflow issues that should be resolved with automation. They will also need to be flexible enough to work different hours or in different areas of the plant until the project is complete. Further, they will be operating the automated production line, so they may have concerns regarding the project that should be addressed. Training on the new equipment will also be essential. By seeking employee input, providing training and addressing concerns, it is possible to foster a positive atmosphere and buy-in for the transition. |
| Test the system | Pilot programs are essential to the success of automation projects. Testing allows issues to be identified and corrected before full deployment, so it doesn’t disrupt the workflow of the entire facility. Testing should be done in stages and should involve employees so they may gradually become familiar with the automated equipment. |
| Monitor performance | Once production line automation is up and running, track performance to be sure it meets the goals and objectives of the project. Consult operators for insight into where further improvements can be made and refine the system accordingly. |
While it is not possible to install an automated production line without any interruptions, it can be done with minimal workflow disruption. Proper planning, enlisting the help of experienced industrial automation integrators, involving and training employees and testing and monitoring the system will help prevent production outages during project deployment. For advice or assistance with your automation plan, please contact the automation pros at JHFOSTER, a Tavoron company, today.
