5 MAJOR REASONS WHY AUTOMATION PROJECTS FAIL
1. NOT DESIGNING THE PRODUCT/PROCESS FOR AUTOMATION
2. NO EQUIPMENT SPECIFICATION – Must have well defined specification for:
Performance – Cycle Rate, Throughput, Up-time, other efficiencies
Documentation and other physical build criteria
3. POOR CONCEPT – NOT WELL THOUGHT OUT
Closing on a concept too quickly without researching the possibilities
Need collaborative, open minded, multi-discipline, team with collective broad backgrounds - cannot have members who want to "WIN" brainstorming/concept sessions
Must probe a variety of technologies and listen to both insiders and outsiders
4. POOR PROJECT MANAGEMENT – BUYER & VENDOR
Inadequate Cost Justification - Must cover all costs - not just equipment - but samples, training maintenance, travel, etc. Due diligence responsibility of Project Manager, Production, Accounting, and Upper Management
Poor communication with Vendor
Poor communication with User Team
Poor Schedule Control
No accountability to schedule by either vendor or team members
Failure to involve the production people in the process
Not enough technical capability in house to handle the technology
Failure to supply vendor with up-to-date drawings and parts
5. ACCEPTANCE CRITERIA – NOT WELL DEFINED
Must define "DONE" - When and under what criteria does the title to the equipment change hands?
Never, never ship the equipment before it is ready.
OUR JOB IS TO MAKE SURE THAT ALL PARTIES SUCCEED!
SUCCESS is a Four Letter Word:
D O N E !
Duraspec™ Project Management Process
1. Receipt of Purchase Order (PO) - Formal Acknowledgement letter to customer
2. Internal Project Kick-off – with Durabotics personnel– formally present project to Durabotics design/build/accounting and other management teams.
3. Project Kick-off with Customer – usually at customer facility a. Introduce Durabotics Design/Build team to Customer Team b. Complete review of proposal, PO and project c. Formalize Schedule – Gantt Chart
4. Bi-Weekly Formal Progress Reports from Project Manager throughout entire project
5. Design/Development Phase – Design process with internal reviews. Procurement will commence. Start releasing and manufacturing key items.
6. Design Review Summary with Customer – Durabotics Design Team and Customer Team – includes complete scale layouts for electrical, mechanical components with bills of materials of major components – presentation of “run-off book” detailing procedures for machine acceptance in Step 9.
7. Build/Procurement/Debug Phase
8. Acceptance at Durabotics - FAT a. 10-minute Unedited Video sent to customer showing machine running without error. b. Video is receipt for customer to come to run-off c. Acceptance “Blue-Book” filled out in advance demonstrating run-in, fit/finish checks. d. Demonstration of all pre-agreed performance criteria e. Provide all documentation to customer f. Sign-off by customer of Acceptance
9. Breakdown for Shipment – Punch List
11. Installation/Start-Up/SAT Tests
a. Installation/Start-Up Assistance
b. Acceptance run-off at Customer Facility – repeat Acceptance Tests in Production Environment.
12. Project Hind-sight Review – with entire Durabotics Team to review/improve process.
Duraspec™ Process for Developing Proposals
1. Initial Meeting with Customer
a. Co-Develop Specification with customer using RIQ form
2. Develop Interactive “Red Pen” Proposal – using standard Durabotics Format stressing
a. Overview – Customer Requirements – Equipment detail description – Sequence of Operation – Project Management – Acceptance Criteria – Schedule – Shipping – Design Concepts.
b. Preliminary Specification
c. Preliminary Cost Analysis
d. Preliminary Cycle Rate Analysis
e. ROI – Return on Investment Calculations
3. Interactive Revisions
a. Revise proposal with customer with interactive revisions, concept alternatives and sometimes prototypes to prove out principles and hone proposal/concept
4. Development of Final Proposal