Published 1/25/2024

How to Build the Right Automation System

Seven considerations when developing an automation solution for your customers.

Troy DeVlieger, President, PFAFF Molds

When developing an automation system for your customers, focus on identifying and addressing the key components that will add significant value. Start by understanding the main challenges your customers face. These challenges often revolve around high worker turnover, rising costs, varying production volumes and sustainability.

Here are seven steps to take when developing an automation solution for your customers:

1. Collaborate to Define the Problem: Work closely with your customers to collaboratively define challenges and requirements. This involves transparent discussions about costs, expenditure and key areas of concern. Leverage the collective knowledge of your team and your customer’s insights.

2. Identify Key Components: For example, reducing worker turnover, addressing rising costs, managing varying production volumes and enhancing sustainability.

Case in Point

In the realm of automation systems, the key component that defines success is the value it adds to the overall process. While investing heavily in automation is tempting, it is crucial to ensure that the investment aligns with the value it brings.

For example, a project focused on automating molding processes in the automotive sector addressed challenges such as varying production volumes. The innovation involved a unique approach, featuring a linear drive rotary table and a vertical molding press. The key goal was to remove the human element from the process, reducing labor, improving flexibility and increasing productivity.

3. Build a Synergized Solution: Synergize information from various sources, including engineers, design teams, project managers and production floor staff. This collaborative approach ensures a comprehensive understanding of the challenges and aids in crafting a solution that aligns with the customer’s needs.

4. Prepare for Innovation: Be prepared for innovation and understand that initial proposals may face rejection. Embrace the iterative process of refining ideas based on customer feedback. The relentless pursuit of innovation involves going back to the drawing board multiple times.

5. Conduct an ROI Analysis: Conduct a thorough return on investment (ROI) analysis, considering factors like reduced labor costs, minimized scrap rates and increased efficiency. Clearly present the potential benefits to the customer, both in terms of cost savings and improved operational outcomes.

A problem for a customer is an opportunity for a mold builder. Here, a PFAFF project manager (on the left) explains the benefits of an automated molding process to his customers.

6. Be Open to Failure: Acknowledge that when venturing into new territory, failure may be part of the process. Learn from rejected ideas and be willing to adapt your approach to find the right solution.

7. Execute with Flexibility: Once the solution is defined and approved, proceed with the execution phase. Be flexible in your approach and open to adjustments as the project progresses.

By focusing on these key steps and components, you can build an automation system that not only meets but exceeds your customer’s expectations.