Requirements Gathering & Feasibility Assessment
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Collaborate with stakeholders to define performance goals, production throughput, product variations, and integration constraints.
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Assess current systems, production environment, and existing infrastructure.
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Conduct risk assessments, ROI analysis, and feasibility studies.
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Identify safety requirements, regulatory compliance needs, and space limitations.
Concept Development & Preliminary Design
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Develop initial system concepts using block diagrams and functional overviews.
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Determine core technologies: robotics, conveyors, sensors, vision systems, PLCs, HMIs, etc.
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Consider part orientation, cycle time targets, material handling strategy, and changeover flexibility.
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Present multiple options or configurations with pros and cons.
Detailed Engineering Design
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Create 3D models of the system using CAD tools (e.g., SolidWorks or Inventor).
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Design mechanical components, control panel layouts, electrical schematics, and pneumatic diagrams.
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Define bill of materials (BOM), part numbers, and standard fasteners.
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Select components and vendors (e.g., robots, actuators, grippers, sensors).
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Simulate the process (digital twin) to validate layout, timing, and interference.
Controls & Software Development
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Develop the PLC and HMI architecture based on sequence of operations.
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Program control logic, safety interlocks, motion profiles, and error handling routines.
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Integrate vision systems or AI if applicable.
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Include remote support features, data logging, and connectivity (e.g., Ethernet/IP, OPC-UA, MQTT).
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Perform bench testing or simulation of controls where possible.
System Fabrication & Assembly
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Manufacture and assemble system components including frames, enclosures, and mechanical subassemblies.
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Route wiring and pneumatic lines to spec.
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Assemble control panels and install electrical hardware.
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Conduct in-house QA inspections on individual subassemblies.
System Fabrication & Assembly
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Manufacture and assemble system components including frames, enclosures, and mechanical subassemblies.
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Route wiring and pneumatic lines to spec.
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Assemble control panels and install electrical hardware.
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Conduct in-house QA inspections on individual subassemblies.
In-House Testing & FAT (Factory Acceptance Test)
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Test the entire system in-house under simulated production conditions.
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Run acceptance criteria including cycle times, throughput, repeatability, and safety validation.
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Document test results and gather customer sign-off during the FAT process.
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Finalize user manuals, maintenance schedules, and operator training materials.
In-House Testing & FAT (Factory Acceptance Test)
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Test the entire system in-house under simulated production conditions.
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Run acceptance criteria including cycle times, throughput, repeatability, and safety validation.
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Document test results and gather customer sign-off during the FAT process.
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Finalize user manuals, maintenance schedules, and operator training materials.
