Implementing a manufacturing automation system is a significant undertaking that transforms production capabilities. Understanding the complete journey from initial concept through production commissioning helps ensure successful outcomes. This guide covers each phase of the automation lifecycle.

Phase 1: Opportunity Identification

Automation projects begin with recognizing opportunities where automation adds value.

Signs Automation May Help

Common indicators include:

  • Labor challenges - Difficulty hiring or retaining operators
  • Quality issues - Inconsistent results despite process controls
  • Capacity constraints - Unable to meet demand with current resources
  • Safety concerns - Operations exposing workers to hazards
  • Cost pressures - Need to reduce production costs
  • Competitive requirements - Customers or markets demanding improved capabilities

Initial Assessment

Before investing in detailed analysis:

  • Document current production processes
  • Identify specific pain points
  • Estimate potential benefits
  • Consider organizational readiness
  • Evaluate available resources

Building the Business Case

Develop preliminary justification including:

  • Estimated investment range
  • Expected benefits (labor, quality, capacity, safety)
  • ROI projections
  • Strategic value beyond financial returns
  • Risk factors and mitigation approaches

Phase 2: Feasibility and Concept Development

With opportunity identified, detailed feasibility assessment begins.

Technical Feasibility

Evaluate whether automation can reliably perform the required operations:

  • Process capability assessment
  • Technology review for suitable approaches
  • Testing with customer parts if needed
  • Risk identification for technical challenges

Economic Feasibility

Refine the business case with detailed analysis:

  • Accurate cost estimates for automation options
  • Realistic benefit projections
  • Total cost of ownership calculation
  • Comparison of alternative approaches

Concept Development

Develop preliminary automation concepts:

  • Process flow definition
  • Equipment selection approach
  • Layout concepts
  • Control architecture outline
  • Integration requirements

Vendor Selection

If using external integrators like AMD Automation:

  • Request for proposal development
  • Vendor evaluation criteria
  • Proposal review and comparison
  • Selection and contracting

Phase 3: Detailed Engineering Design

Approved concepts proceed to detailed design.

Mechanical Engineering

Create complete mechanical designs:

  • 3D CAD models of all custom components
  • Fixture and tooling design
  • Frame and structure engineering
  • Material handling systems
  • Utility systems (pneumatic, hydraulic)
  • Guarding and safety enclosures

Electrical Engineering

Develop complete electrical systems:

  • Electrical schematics and wiring diagrams
  • Panel layouts and component selection
  • Power distribution design
  • Sensor and actuator integration
  • Network architecture

Controls Engineering

Design automation controls:

  • PLC programming approach
  • Robot program development
  • Vision system configuration
  • HMI screen design
  • Safety system programming
  • Communication protocols

Simulation and Virtual Commissioning

Modern projects leverage digital twin technology:

  • Complete system simulation
  • Cycle time validation
  • Collision detection
  • Program debugging before hardware
  • Operator training preparation

Design Reviews

Formal reviews ensure quality:

  • Internal design reviews
  • Customer design reviews
  • Safety reviews
  • Compliance verification

Phase 4: Procurement and Fabrication

Physical realization of the design begins.

Component Procurement

Acquire all required materials:

  • Long-lead-time items (robots, drives, PLCs)
  • Commercial components (sensors, pneumatics)
  • Custom fabricated parts
  • Electrical components
  • Software licenses

Mechanical Fabrication

Manufacture custom mechanical components:

  • CNC machining of precision parts
  • Welding and structural fabrication
  • Sheet metal for enclosures
  • Surface treatment and finishing

Panel Building

Construct electrical control panels:

  • Component mounting
  • Wiring per schematics
  • Labeling and documentation
  • Pre-installation testing

Assembly

Integrate mechanical systems:

  • Machine base assembly
  • Robot and equipment installation
  • Fixture and tooling integration
  • Utility installation
  • Guarding assembly

Phase 5: System Integration

Mechanical and electrical systems come together.

Electrical Installation

Connect power and controls:

  • Panel installation
  • Field device wiring
  • Robot cabling
  • Network connections
  • Safety circuit wiring

Controls Integration

Bring the system to life:

  • PLC program download
  • Drive configuration
  • Robot programming and teaching
  • Vision system setup
  • HMI commissioning

System Debugging

Systematic issue resolution:

  • Input/output verification
  • Motion testing and tuning
  • Sequence debugging
  • Safety system validation
  • Error handling verification

Process Development

Optimize for production parts:

  • Process parameter development
  • Cycle time optimization
  • Quality verification
  • Capability studies

Phase 6: Factory Acceptance Testing

Formal validation before shipment.

Test Plan Development

Define acceptance criteria:

  • Functional requirements checklist
  • Performance specifications
  • Quality requirements
  • Safety validations
  • Documentation requirements

Test Execution

Demonstrate system capability:

  • Complete functional testing
  • Cycle time verification
  • Quality sampling
  • Safety function validation
  • Endurance runs

Customer Witness

Customer representatives observe:

  • Test execution observation
  • Questions and clarification
  • Issue identification
  • Conditional acceptance if needed

Issue Resolution

Address any deficiencies:

  • Punch list documentation
  • Corrective actions
  • Retest as required
  • Final acceptance

Phase 7: Installation and Startup

The system moves to production.

Site Preparation

Customer prepares the facility:

  • Floor preparation and anchoring provisions
  • Utility connections (power, air, network)
  • Environmental controls if required
  • Material handling connections
  • Operator areas

Rigging and Placement

Professional installation:

  • Equipment transportation
  • Precise positioning
  • Leveling and anchoring
  • Section connections for multi-piece systems

Utility Connection

Connect required services:

  • Electrical power
  • Compressed air
  • Cooling if required
  • Network connections
  • Auxiliary systems

Field Startup

Reestablish operation:

  • Post-transport verification
  • Utility verification
  • System power-up
  • Functional checkout
  • Safety verification

Phase 8: Production Commissioning

Transition to production operation.

Operator Training

Prepare production personnel:

  • System operation procedures
  • Manual mode operation
  • Quality verification procedures
  • Basic troubleshooting
  • Safety awareness

Maintenance Training

Prepare maintenance staff:

  • Preventive maintenance procedures
  • Spare parts identification
  • Common issue diagnosis
  • Adjustment procedures
  • Vendor contact information

Production Ramp-Up

Gradual transition to full production:

  • Initial supervised operation
  • Process optimization
  • Production rate increase
  • Shift-by-shift handover
  • Full production release

Site Acceptance

Formal production validation:

  • Performance verification in production
  • Documentation completion
  • Training confirmation
  • Punch list resolution
  • Warranty commencement

Phase 9: Ongoing Support and Optimization

The relationship continues after commissioning.

Warranty Support

Initial period support:

  • Technical assistance
  • Remote diagnostics
  • Warranty repairs
  • Software updates
  • Performance optimization

Preventive Maintenance

Establish maintenance programs:

  • Scheduled maintenance procedures
  • Spare parts inventory
  • Predictive maintenance monitoring
  • Performance tracking

Continuous Improvement

Ongoing optimization:

  • Production data analysis
  • Cycle time improvements
  • Quality enhancements
  • Uptime improvements
  • Capability expansion

Lifecycle Management

Long-term equipment health:

  • Upgrades and retrofits as technology advances
  • Capacity expansion as demand grows
  • Product changes as offerings evolve
  • End-of-life planning

Keys to Successful Implementation

Strong Project Management

Effective coordination throughout:

  • Clear project plan with milestones
  • Regular status communication
  • Issue escalation processes
  • Change management procedures

Customer Engagement

Active participation improves outcomes:

  • Timely decision-making
  • Resource availability for reviews and testing
  • Accurate information sharing
  • Commitment to schedule

Realistic Expectations

Understanding typical project dynamics:

  • Engineering changes are normal
  • Debugging takes time
  • Production ramp-up is gradual
  • Optimization is ongoing

Experienced Partners

Working with knowledgeable integrators:

  • Domain expertise in your industry
  • Technical depth across disciplines
  • Proven project execution
  • Long-term support capability

AMD Automation brings decades of experience implementing manufacturing automation systems across automotive, medical device, aerospace, electronics, consumer products, and food and beverage industries.

Ready to begin your automation journey? Contact us to discuss your project. We'll guide you from concept through production commissioning and beyond.