The engineers at Mus Corp. have done the impossible—they’ve invented a better mousetrap. It’s got all the latest anti-rodent gizmos, and if the price is right, consumer demand could exceed 2 million assemblies per year.

Mus engineers conclude that automation is the only way to keep up with demand. All they have to do is build or buy an automated assembly system that can produce the mousetrap quickly, reliably and economically. They also have to get the system up and running before their competitors can introduce their own better mousetraps. Piece of cake, right?

Not at all. For many assemblers, automation projects are anything but simple. Process problems, cost overruns and delays are a few of the pitfalls of implementing automated assembly systems. Without careful planning and the cooperation of suppliers, these pitfalls can catch assemblers unaware.

The first steps in obtaining a system are to define goals and set parameters. What are you hoping to accomplish with the system? A manufacturer that wants to save labor costs or increase production may have different needs than a company that wants to improve quality. Early in the process, it’s a good idea to realistically assess the technical capabilities of your workforce. Assemblers that are venturing into automation for the first time may want to avoid highly sophisticated systems.

Assemblers should note how many parts must be assembled, how much of the product can be assembled automatically, and whether the product lends itself to automated assembly. How much of the product will be produced or assembled in-house, and what will come from suppliers? If the product has variants, they should be noted.

When assessing the product’s design, engineers should think about how the parts will be fed. Are the parts fragile or easily marred? What are the tolerances? Can a feature be added to make the parts easier to feed or handle? Can any parts be consolidated?

There’s a lot to think about. This eBook will help you get a handle on it. Articles will cover process planning, equipment specification, flexibility, parts feeding and other topics. And, at the end, you can read about actual systems that are running right now. Whether you’re an experienced manufacturing engineer or a newbie, we hope this eBook will provide food for thought.

John Sprovieri
Chief Editor