Embarking on a custom automation journey is like embarking on a precision collaboration adventure.A successful project can significantly enhance efficiency and ensure consistent quality,while overlooking details may lead to delays,cost overruns,and even idle equipment.Choosing a partner is crucial,but before shaking hands,delving into key technical details is a wise move to mitigate risks and lay the foundation for success.The following eight questions are designed to help you clear the fog and establish a clear,consistent technical consensus with potential suppliers.
How Well Does the Core Objective Fit with Existing Processes?
• Key Point:Automation is not a magic key.Clearly define the most pressing issues you need to address(such as production bottlenecks,high-intensity manual operations at specific stations,consistency in metal part machining),and thoroughly analyze current processes(including manual steps,cycle times,material flow methods).
• Must-Ask Details:"How will you evaluate our existing processes to determine the optimal points for automation intervention and the best value-maximizing solutions?Specifically,which parts of the process will this custom automation system replace or optimize?"
• Risk Mitigation:Prevent the automation solution from being disconnected from real needs and becoming an expensive"ornament."
How Can We Confirm the Depth of Compatibility with the Existing Environment?
• Key Point:The new system is not an isolated island.It needs to seamlessly integrate into your workshop environment.
• Must-Ask Details:"Please provide a detailed plan and timeline for inspecting the actual factory conditions(including space dimensions,floor load capacity,type/capacity of energy supply,compressed air interfaces,network access points,lighting conditions,safety corridors).What are the specific technical plans and feasibility assessments for integrating the system with existing material handling equipment(e.g.,AGVs,conveyors),warehousing systems(WMS),and upper-level MES/ERP systems?"
• Risk Mitigation:Avoid costly renovations and project delays due to mismatches in space,energy,or data interfaces.
How Can We Ensure the Machining Precision and Long-term Reliability of Core Components?
• Key Point:The skeleton and joints of the automation system—precision structural components and moving parts—are crucial,especially when involving precision machining of metal parts.
• Must-Ask Details:"What materials(e.g.,aerospace aluminum,specific steel grades)will be used for critical load-bearing structural components and precision moving parts(such as linear module bases,rotary table bases,high-precision fixture bodies)?Will these mainly rely on purchased standard parts or in-house CNC machining?What is the machining capability for in-house metal parts(highest precision,maximum size,typical surface roughness)?What are the brands and selection criteria for key purchased components(such as bearings,guides,servo motors)?Are there plans for expected life calculations or accelerated wear tests for critical moving parts?"
• Risk Mitigation:Prevent system performance degradation,frequent breakdowns,and downtime due to insufficient strength,precision deviations,or premature wear of core components.
How Can Process Adaptability Address Future Changes?
• Key Point:Products are not static.The automation system needs a certain degree of flexibility.
• Must-Ask Details:"Which specific product models is the current solution optimized for?What adjustments will the system need if there are design changes to the product(such as critical dimensions±0.1mm,material changes,addition/removal of small features)?What is the estimated range of adjustment time and cost?What dimensions of adjustability has the system reserved(such as fixture quick change,adjustable range of program parameters,tolerance of vision recognition)?"
• Risk Mitigation:Avoid the entire system becoming ineffective or requiring expensive modifications due to minor product changes,losing its investment value.
How Can Mass Production Ramp-up and Sustainable Production Be Ensured?
• Key Point:Successful commissioning does not equal successful mass production.Stability and maintainability are equally critical.
• Must-Ask Details:"What is the project's production capacity target(pieces per hour/day)?How long is the expected ramp-up period to reach stable mass production(meeting yield and cycle time requirements)?What is the theoretical OEE(Overall Equipment Effectiveness)target for the system design?For critical wear parts(such as sensors,grippers,specific CNC precision machining fixture components),what is the expected replacement frequency and spare parts strategy?Is there a clear plan for the content,frequency,and skill requirements of routine preventive maintenance(PM)?"
• Risk Mitigation:Avoid the project being stuck in the commissioning phase without reaching production capacity,or frequent downtime after production due to improper maintenance or lack of spare parts.
Are Human-Machine Interaction and Safety Design Sufficient and Compliant?
• Key Point:Safety is the bottom line,and ease of operation affects efficiency.
• Must-Ask Details:"Please provide a detailed explanation of the methods and results of the safety risk assessment(e.g.,for mechanical pinching,entanglement with moving parts,electrical hazards).What specific safety features will the system integrate(such as safety light curtains,emergency stop buttons,safety door locks,two-hand start)?Does it comply with specific safety standards in the target market(such as the EU's Machinery Directive,OSHA standards)?Is the logic of the human-machine interface(HMI)design clear?What training will operators need to safely and efficiently operate and handle common alarms?"
• Risk Mitigation:Eliminate safety hazards,ensure employee safety,and reduce efficiency losses or misoperations caused by complex operations.
How Can Quality Control Be Seamlessly Integrated and Effectively Traced?
• Key Point:Automated production must ensure controllable quality.
• Must-Ask Details:"What online or offline quality inspection methods has the system integrated(such as machine vision for size/presence checks,force sensors for press-fit process monitoring,laser distance measurement)?How will inspection results be fed back in real-time to control the production process(e.g.,automatic rejection of defective products)?How are key process parameters(such as tightening torque,press-fit displacement curves)and inspection results recorded,stored,and traced at the product/batch level?What are the formats and storage periods for traceability data?"
• Risk Mitigation:Prevent the production of large quantities of defective products that cannot be detected and traced in time,causing significant losses.
How Can Knowledge Transfer and Long-term Support Be Implemented?
• Key Point:Project delivery is not the endpoint;you need to master the ability to manage the system.
• Must-Ask Details:"What specific technical documents are included in the project delivery(such as detailed electrical schematics,pneumatic circuit diagrams,annotated PLC/HMI programs,mechanical assembly drawings,maintenance manuals,spare parts lists)?What types and depths of operation and maintenance training will the supplier provide(targets,duration,content,assessment)?What is the technical support response mechanism after commissioning and warranty period(e.g.,remote support response time,on-site service terms)?Are there long-term service agreements(SLAs)available?"
• Risk Mitigation:Avoid low system utilization or even paralysis after project delivery due to technical black boxes,missing documentation,or inadequate support.
Conclusion:Make Technical Dialogue the Cornerstone of Project Success
Asking these eight questions is not a challenge to the supplier's capabilities but the beginning of a transparent and mutually trusting cooperative relationship.The value of a sincere and in-depth technical dialogue far exceeds that of an impressive proposal.Clearly defining these core details of custom automation projects can effectively filter out partners who truly understand your challenges,possess solid technical capabilities,and a service-oriented mindset.When both parties reach a deep consensus on these technical levels,the project blueprint becomes truly clear,and the path to success becomes more solid.This is not only about risk mitigation but also about laying the foundation for your custom automation solution to be reliable and efficient in the long run.