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The Role of Process Development in Automation Presentation

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Advent Design Corporation

The document discusses process development for automation. It defines process development as determining the sequence of operations and parameters to ensure a manufacturing process produces products within specifications. It notes that automation will change tools, sequences and remove the human element from processes. It advises to identify current manual processes carefully, qualify and test any process changes, and minimize risks when developing automated processes. It provides tips on machine design for process development, including using programmable controllers, sensors and flexible framing.

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The Role of Process Development in Automation Tom Lawton President ADVENT DESIGN CORP.
Process Development What is process development? The sequence of operations and parameters required for each operation to ensure that the manufacturing process produces a product within specifications. 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 to transform the product will change Sequence of steps may change Absence of Human Element Intellect Dexterity Adaptability
Identify Your Process Understand what’s changing Quantify Parameters Repeatability Evaluate manual processes carefully Quality Requirements Environmental Effects Be willing to make product design changes You will miss things during the identification process.
Qualify and Test Process Changes Manufacturing Process Changes Product Design Changes Wherever possible integrate process changes into the existing manufacturing process first Every process change has unanticipated consequences Understand the consequences before cutting metal
Minimize Risk The more you change your product or process the higher the risk The more processes you link together the greater your down time 99.910 = 99% @ 100 parts/minute = down every minute
Common Pitfalls Underestimate the human element Incoming parts not within specification Development components not truly representative of production components Process is not repeatable Product Design changes
Machine Design Select a transport system based on the requirements of the process.
Robot Advantages 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 Inline Advantages 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 Inline Advantages Disadvantages Best method when Very high cost when combining manual pallets required and automatic Slower than operations synchronous Allows accumulation between stations
Walking Beam Advantages 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 Don't use PLC or other combine operations if programmable at all possible controller - Linking operations oversize PLC limits flexibility use Op Interface because if effects the other processes include extra stations use mechanical cams use sensors - when in or linkages doubt include a sensor
Machine Design for Process Development (Cont.) Do Don't use pneumatic directly connect actuators where electrical sensors or possible actuators - go through use servo actuators PLC when you need to control motion use flexible framing (Bosch or other) use off the shelf subsystems when possible
In Summary Understand your process thoroughly Don’t underestimate the human eliminate Test manufacturing process and product design changes Minimize risk Design to monitor and adjust process parameters

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The Role of Process Development in Automation Presentation

  • 1. The Role of Process Development in Automation Tom Lawton President ADVENT DESIGN CORP.
  • 2. Process Development What is process development? The sequence of operations and parameters required for each operation to ensure that the manufacturing process produces a product within specifications. Define transformation requirements of each step of the manufacturing process Define the sequence of steps
  • 3. Automation Will Change your Process Why does the manufacturing process change? Tools used to transform the product will change Sequence of steps may change Absence of Human Element Intellect Dexterity Adaptability
  • 4. Identify Your Process Understand what’s changing Quantify Parameters Repeatability Evaluate manual processes carefully Quality Requirements Environmental Effects Be willing to make product design changes You will miss things during the identification process.
  • 5. Qualify and Test Process Changes Manufacturing Process Changes Product Design Changes Wherever possible integrate process changes into the existing manufacturing process first Every process change has unanticipated consequences Understand the consequences before cutting metal
  • 6. Minimize Risk The more you change your product or process the higher the risk The more processes you link together the greater your down time 99.910 = 99% @ 100 parts/minute = down every minute
  • 7. Common Pitfalls Underestimate the human element Incoming parts not within specification Development components not truly representative of production components Process is not repeatable Product Design changes
  • 8. Machine Design Select a transport system based on the requirements of the process.
  • 9. Robot Advantages 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
  • 10. 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
  • 11. Synchronous Inline Advantages 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
  • 12. Asynchronous Inline Advantages Disadvantages Best method when Very high cost when combining manual pallets required and automatic Slower than operations synchronous Allows accumulation between stations
  • 13. Walking Beam Advantages Disadvantages Very cost effective in Hard to use if pallet no pallet required required Enables different part fixturing in each station
  • 14. Machine Design for Process Development Do Don't use PLC or other combine operations if programmable at all possible controller - Linking operations oversize PLC limits flexibility use Op Interface because if effects the other processes include extra stations use mechanical cams use sensors - when in or linkages doubt include a sensor
  • 15. Machine Design for Process Development (Cont.) Do Don't use pneumatic directly connect actuators where electrical sensors or possible actuators - go through use servo actuators PLC when you need to control motion use flexible framing (Bosch or other) use off the shelf subsystems when possible
  • 16. In Summary Understand your process thoroughly Don’t underestimate the human eliminate Test manufacturing process and product design changes Minimize risk Design to monitor and adjust process parameters