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