How to Implement Automation in Brownfield Facilities Without Disrupting Operations
Planning and testing will help keep operations running smoothly.
Why Brownfield Automation Is So Complex
You’re in a brownfield operation, and you’re about to embark on the implementation of new automation. While the payoff will be worthwhile, getting to that point is complicated, and rarely goes off perfectly. But integrating new automation into an existing operation is possible, and when carried out well, can involve little disruption.
Start with a Detailed Pre-Installation Plan
In part three of our series on just this topic, we’re going to address how to prepare your physical space for the new equipment. This begins with your integrator and internal Project Manager to properly scoping and planning for the installation.
Map Out Entry Points and Delivery Timing
Final project plans should be agreed upon with a pre-site survey with the rigger/vendor to understand which entry into the building makes the most sense and if there are any obstacles to watch for, like columns? And is there a limited window of time in which the deliveries can take place? Make drawings of the floor space so that nothing is left as a surprise.
Best Practices for Staging and Delivery
Often, the most convenient time to deliver the new materials is the weekend. Your shifts might wrap up around 8 p.m. on a Friday, for instance, and then you can spring into action bringing in the staging materials. You’ll likely then have until late Sunday night or very early Monday morning to work on the installation; however, in some cases that won’t be enough.
Determining the best time for delivery and installation in advance is a critical part of the process and in many cases, having the packaging pre-labeled in advance to coordinate a systematic approach to bringing the product in will help eliminate unnecessary movement and shuffling within the facility.
FAT vs. SAT: Testing Automation Before and After Install
Keep in mind that the OEM and integrator will work to simulate the new operations ahead during factory acceptance testing (FAT). This is to ensure the new system is going to work prior to delivery and fixes aren’t taking place after installation. A second test will take place after installation during site acceptance testing and after being fully integrated with the overall solution.
In that time, your integrator will bring in the new equipment, stage it, and then begin assembling. In many cases, the final electrical connections for automation systems should be performed by a licensed electrician to avoid any unexpected issues. After the machine has been fully assembled, including all hardware and wiring, testing will begin, starting with a dry test (cycling) followed by a material test if necessary. Therefore, it is crucial to ensure that the OEM integrator has everything they require during the testing phase to prevent wasting valuable time.
Final Sign-Off and Operator Training
After the SAT and customer sign-off that the equipment is operational, operator training will take place. All this effort is outlined succinctly within an agreed upon project plan to ensure a seamless installation and transition to operations.
While not every issue will pop up during testing, the goal is to identify the major ones, thus avoiding big problems once live. Then, you’re only left with the small issues to tackle.
Measuring Success Post-Implementation
The stakes are high when implementing new automation as now the rubber meets the road and the identified key performance indicators (KPI’s) that were agreed upon will now be measured. Your customers have expectations of when their products will go out the door.
Source: Ross Timmerman, TGW Group
For more information about the Solutions Community: mhi.org/solutionscommunity
For further articles from the Solutions Community:
MHI Solutions Community Annual Meeting Panel
Don’t Overlook the Condition of Handhelds
Integrating New Automation- Part 1
Implementing a Warehouse Control System (WCS)
Is it the Right Time to Automate Your DC?
Condition Monitoring is Expanding
