One of the most valuable benefits of a modular microfactory is the agile delivery process. It can provide you with ~ 30% faster deployment time and radically lower investment costs and risks than a customized automation solution. This blog describes the microfactory delivery process and its advantages.
Introduction
When manufacturers switch from a custom-automation world to a microfactory, they are surprised about its fast deployment time. Our customers have gained up to 30% faster deployment time with a microfactory when compared to an estimated deployment time of a similar traditional customized automation solution. Such a big time-saving, however, requires a thought-through, field-proven delivery process. Here’s a rundown of our six-step microfactory delivery process
Microfactory Delivery Process
1. Manufacturing Process Analysis
The delivery process starts from a manufacturing process analysis. Your current manufacturing process is analyzed, and further optimizations are proposed to increase efficiency and quality. We always consider products and processes hand in hand to create the best possible design for manufacturing and assembly (DFMA).
2. Automation Design
An optimal automation design is always a combination of two things. You must know the latest technologies and methods inside-out and have in-depth and hands-on design experience. We always put our complete expertise and experience in the game when designing automation for our microfactory customers. Typically this involves refining a customer’s production requirements, creating new streamlined processes from scratch, or updating existing processes. The goal is to find the best possible solution for your needs while avoiding sub-optimal compromises.
3. Pre-assembly and Testing
In the pre-assembly and testing phase, we build the designed microfactory solution at our factory from the ground up using the specified equipment, software, interfaces, and protocols. The pre-assembled system is a full (100%) copy of the production system deployed at your site. All the machines are thoroughly tested in a so-called factory acceptance test (FAT). Shipping of the microfactory to your site takes place only upon the customer’s acceptance and approval.
4. On-site Installation and Ramp-up
After the microfactory is successfully shipped, the EID Robotics field deployment team installs and ramps it up at your premises. Thanks to our thoroughly planned delivery process, modularized platform, and standardized interfaces, the on-site microfactory installation time is typically very short, even one day. The installation time, however, is highly dependent on the complexity of the system.
5. Training
Upon completed installation and ramp-up, your production staff is trained for operating and maintaining the microfactory. The detailed instructions and user-friendly graphical user interfaces (GUI) make operating ANT Plant microfactory intuitive for professionals.
6. Maintenance and Optimization
Despite fully accepted and commercially operational plant, the microfactory delivery process doesn’t stop just yet. As with any automation system, maintenance and optimization are continuous processes. EID Robotics team remains at your reach throughout the operational life-cycle, takes care of maintenance, and helps you to optimize the process. This allows you to concentrate on developing products and growing your business. The maintenance service includes a full-time warranty, scheduled services, spare parts, 24/7 remote support availability, and on-site visits when needed.
Microfactory vs. Customized Automation Solution – Comparing Delivery Processes
Why is the microfactory delivery process faster, less costly, and less risky compared to a custom solution? In a modular microfactory, both a single cell and the entire line are modular. The production line consists of modules, each with its pre-tested application(s). The interfaces between the modules are standardized and precise, making combining modules easy. This minimizes installation time at the production site and reduces costs significantly.
In a modular microfactory delivery process, the basic modules can be ordered right at the beginning of the project. This speeds up the delivery process because the assembly can be started although the design is still in progress. Thus, the workload is more evenly distributed across the project. In a traditional custom-automation project, parts can be ordered only after completion of the design.
A modular microfactory is assembled from main modules and connecting them at the production site does not require teaching robots and other actuator points separately.
The agile delivery process – with shorter duration, reduced costs and lower risks – clearly is one of the main microfactory benefits manufacturers most value!
In Conclusion
Based on our experience, the total duration of the microfactory delivery process can be up to 30% shorter than with a traditional custom solution. The onsite ramp-up time in customer premises can be more than 90% faster thanks to a modular system. Despite the simplicity and fast deployment, microfactory enables high-quality manufacturing – for our customer SenseAir, a microfactory increased product quality and opened new customer segments!
As you know, each case is unique in the automation world. Find out how much you can save time with a modular microfactory – contact us!
