AAC for Manufacturers

04/10/2023 AAC Confidential 1

Automation Assistance and Consulting LLC

Michael Greene

Automation Consultant - Owner

204/10/2023 AAC Confidential

ObjectiveAssist Manufacturers

“Lacking time, expertise and resources”- Improve Existing Manufacturing – Engineering Study

- Cost Bid Submittal and R.O.I. Analysis- Final Report and Presentation

Assist Machine Builders“Under staffed or lack experience”

- Support Application Engineering in all Functions- Assist Sales Dept. with New Markets, Projects and Sales Presentations

“From Concept to Production AAC can Provide Assistance in Each Stage of Automation Development”


Assist ManufacturersDetermine Automation Needs

EngineeringStudy

CurrentSystem

Assessment

ProjectInitialization

DatabaseAssessment

ProfilesGeneration

SystemConcepting

System Specand RFQ

FeasibilityStudy

FinalReport


Assist Manufacturers

Lean Manufacturing“Reduce Operating Costs”

- Continuous Improvement- Waste Removal- Standardized Work

Source: Aberdeen Group, Feb. 2008

Top Pressures All Respondents

Need to reduce overall Operating Costs 79%

Demand for shorter lead times 43%

Operational process complexity 19%

Globalization 18%

Demand for higher quality products 16%

We Will Always Consider:


Assist Manufacturers

Lean Manufacturing“Lean as a holistic approach requires discipline and attention to each layer of the lean philosophy”

TOC, JIT, DBR, SMP, Lean Accounting, Flow Manufacturing

Eliminating Waste, Visual Cues, The Five S’s, Error Proofing,

Six Sigma, Documented Procedures and Instructions

Define Value, Map the Value Streams, Make Activities

Flow, Respond to Customer Demand, Continuously

Improve (Kaizen)

Source: Aberdeen Group, Feb. 2008

Business Value StreamLayer

Business ImprovementLayer

Business StrategyLayer

LeanApproach

We Will Always Consider:


Assist ManufacturersEngineering Study

“What AAC Can Accomplish”

AAC has years of practical experience conducting field engineering studies to specify the optimum system to meet your strategic business goals.

The primary phases of the design process consist of a system configuration analysis, system design, and system implementation. Each study and its results are based upon the current and forecasted volumes for your specific business. We work closely with your team and promote a high level of participation in the design process so that each evaluation is tailored to your company’s needs.

“From Concept to Production AAC can Provide Assistance in Each Stage of Automation Development”


Engineering StudyStage 1 – Project Initialization

“The first stage of the engineering study involves assigning working committee members, communicating the project scope, and

establishing roles and responsibilities for all involved”

A Orientation – Review the objectives of the analysis and methodology to be employed, conduct tours of your facility to establish a sense of direction and purpose.

B Establish a Project Team – Assign a project manager with engineering and administration support personnel. The roles and responsibilities of each team member are reviewed in this stage.

C Client Direction for Change – Discuss your strategy for distribution and your desired results from an improved operation. We will also assess your quantitative and qualitative evaluation criteria of operational performance as well as address diversity of perspectives.

D Identify Critical Success Factors – Identify the factors which your company must do well or continue to do well in order for your organization to sustain and increase customer service, growth, and profitability.


Engineering StudyStage 2 – Current System Assessment

“In this early stage we need to know your business and where it’s going. We conduct several facility walk-throughs, perform various activities as operators, and study your current business practices.”

A Facility Layout – AAC will develop accurate, as is, drawings of your current facility. Specific focus will be given to the interface between construction and facility operations.

B Management and Operator Interviews – AAC will identify relevant strategic and operational issues that will potentially impact the process of the System Configuration Analysis and the final recommendations.

C Document Material Flow – AAC will document the types of storage and material handling equipment used currently. Material flows will be mapped on a CAD drawing within the operational area. Preliminary space requirements will be determined.

D Document Information Flow – AAC will document the information systems environment within the operation. Specific emphasis is placed on processing steps that require paper documents or interface with information systems.

E Compile Results – AAC will summarize the results of all the previous engineering studies and present a detailed schedule for the remainder of the System Configuration Analysis.


Engineering StudyStage 3 – Database Assessment“In this stage the existing database (if any) is reviewed to determine

areas of weakness including lack of information and undesirable formats.”

A Request for Operating Data – AAC will request formats of electronic data including product master displays, production data displays, and HMI displays at work stations. From this data, AAC produces detailed record layouts to echo back its understanding of the data being provided.

B Request for Documented Data – Documented data (hard copy reports) includes activity, cost, operating budget, and performance information.

C Database Hierarchy – Evaluate and understand the type and functionality of existing database hierarchy. Understand the relationship of database hierarchy with other areas of customer’s business.


Engineering StudyStage 4 – Profiles Generation“This stage involves concepting a computer database model to gain a full understanding of the key issues, and to examine the practical

alternatives.”

A Develop Current Profiles – AAC will concept a computer database format which maintains information about the current period demand profiles.

B Project Future Requirements – ACC will help determine all future profiles based on levels of activity for the facility from client’s business plans, forecasts, and objectives.

C Incorporate Future Requirements – Original concepts will be altered to incorporate the latest profile requirements determined by team members and client management.


Engineering StudyStage 5 – System Concepting

“It is during this important stage that conventional and/or automated system solutions are developed and evaluated.”

A Execute Configuration Analysis – AAC will utilize the various activity profiles in determining how to structure manufacturing operations. In addition, we will develop the most appropriate product retrieval and delivery configuration based on product velocity and inventory needs.

B Prepare Conceptual Drawings – Based on all previously gathered information, ACC will create a system layout of the assembly/test equipment, material handling and material flow. This equipment may be automated, mechanized, manual-assisted or manually operated.

C Review Alternative Concepts – The original equipment layout will be presented to the team for analysis. Alternatives are reviewed in terms of projected equipment, systems, facility alterations, and staffing needs.


Engineering StudyStage 6 – System Specification and RFQ

“Final recommendations are documented in a system specification and RFQ for establishing costs.”

A Refine Best System Design Alternatives – All previously created documents and equipment layouts will be revised to incorporate the final design alternatives.

B Equipment Specification – Based on client’s in-plant and corporate specifications, a system specification will be written by AAC describing the system in detail. This specification will describe the mechanical, control, pneumatic, hydraulic, and data acquisition of the system. It will demand that “best practices” be used throughout the systems and that all components meet or exceed client’s preferred component lists. Where client does not have a specific preference for components or major purchased items, AAC will specify brand and model based on our experience.

C Seek (3) Outside Bids for System Cost – AAC will meet with three qualified machine builders and present an RFQ for the specified system. The RFQ will include the system specification, client’s expectations, payment terms, and clients standard terms and conditions for major purchased equipment. The RFQ will ask for price, delivery, floor space required, power and air consumption, training client’s personnel and turnkey installation.


Engineering StudyStage 7 – Feasibility Study

“We recommend only the most appropriate and cost effective solutions. A cost benefit analysis will be performed at this stage.

A Estimate System Costs – For all equipment, systems and facility alterations AAC will define investment, installation, operating and maintenance costs.

B Economic Analysis with Client – Each client has different methods of performing economic analysis. Therefore, ACC requests that you allow us to work with your accountants in the analysis of the system since they are aware of your company’s specific economic guidelines, approved approaches for savings, policy on depreciation and corporate taxes. Other areas of analysis include, but are not limited to: labor reduction, moving of shift start and end times for more efficient operation, and better use of labor with respect to burden rates.

C Perform Qualitative Analysis – AAC will perform final qualitative analysis on the basis the established evaluation criteria discussed under Stage 5.

D Present Final Draft To Team – AAC will present a final draft of the “system qualitative and economic analysis “ to the team for improving content and presentation.


Engineering StudyStage 8 – Final Report

“ A final report is prepared covering assumptions, requirements, and analysis as well as alternative system concepts and recommendations.”

A Develop Implementation Plan – AAC will establish a detailed plan for a stepwise implementation to achieve minimal disruption of existing operations.

B Update System Drawings – AAC will update all drawings related to the system reflecting any and all changes or enhancements incurred during the bid phase.

C Prepare Final Report – AAC will prepare final report with focus on the Executive Summary and Implementation Plan.

D Delivery Final Presentation – AAC will deliver final report and presentation to client. At the completion of this stage, the client owns the engineering study and has the option of waiting or continuing on with the building of the equipment. Since AAC has the most knowledge about the functionality of the system and is most aware of the bid requirements and agreements, we ask that AAC be allowed to participate in all final negotiations and contracts with the machine or system builder.


Meeting the Needs

My Experience

Application Engineering- 16 Years Experience

Estimating- 9 Years Experience

Sales & Management- 7 Years Experience

6 years

3 Year

1 Year

1 Year

5 Years

1 Year

1 Year

7 Years1 Year

3 Years

3 years

Sales & Management

Estimating

Application Engineer


My Previous Employers

Gilman Engineering and Manufacturing Co. (Giddings & Lewis)

Lamb Assembly & Test (Unova)

Calvary Automation Systems, Inc.

Johann A. Krause (ThyssenKrupp)

Advanced Assembly Automation (ATW)

Cincinnati Automation & Test (MAG)

Gilman Engineering and Manufacturing Co.


My Strength In Experience


Markets Served

Aerospace

Automotive

Medical

Solar Energy

Diesel Engine

Consumer Product

Material Handling


Automation Assistance and Consulting LLC

“Providing Assembly Automation Assistance at a Detailed Level”

3554 Cricketeer Dr.

Janesville, WI 53546

PH: 608-359-6008

Email: [email protected]

Website

www.autoassistconsult.com

AAC for Manufacturers

Documents

Transcript of AAC for Manufacturers