Things to Look for When Choosing a Systems Integrator

August 2020

Things to Look for When Choosing a Systems Integrator

Let’s say you have been tasked with automating a process within your organisation. Assuming you don’t have the in-house resources to carry out the work, you will need to identify and choose an external systems integrator or machine builder.

The chances are that if you are making widgets, then you’ve probably searched for “widget assembly machines” or something that relates to exactly what you need. The likelihood of you finding an exact match is probably remote unless your product requires a standard automation approach. This is where you may have to consider selecting an integrator that designs and builds a bespoke solution created to suit your exact needs and have the correct functionality.

Defining Your Requirements

There are many ways to start the process, but the key element here and before you even look to choose a system integrator, it is extremely important that you define exactly what you need. This would take the form of a URS (User Requirement Specification) detailing the inputs and outputs of the system. This document would not define how the end solution would function and look but would share pertinent information regarding throughputs, efficiencies, crucial process steps, preferred hardware, and final inspections.

Partnership

The key to a successful project is a good, sound partnership. You are looking for a company that is transparent on both commercial and technical fronts. If this is evident in a system integrator from the first meeting, then there is a good chance that this approach will be carried throughout the project. A company that is willing to show detailed cost breakdown and in-depth technical information provides two advantages in the selection criteria when choosing an integrator:

1. Detailed cost breakdown: This demonstrates that they have gone through a detailed costing based on the solution. This ultimately means that there is less chance of budgets stretching once they are initiated.
2. Detailed overview of the system: A reasonable amount of detail in a concept drawing or specification would also indicate that the potential partner has understood the requirements and has relevant project experience.

Capabilities

The overall technical and professional capabilities are a major deciding factor when selecting a systems integrator partner. It is important that they have resources in-house to help them react to issues when they arise. A systems integrator that can demonstrate its capabilities for design, panel build, software, manufacturing, and commissioning, in theory, is more likely to succeed as a partner.

Reliance on subcontractors by your automation partner may cause issues towards the latter stages and post-commissioning. Having all the skills in-house enables the integrator to better plan your project lifecycle, as they will not be relying on working around contractors. A good example of this is software. A bespoke automation project is essentially designing and building a machine from scratch.

The software side brings together all the electrical and mechanical designs and makes the system work. Even with the best machine function flow charts, timing diagrams, validation, etc., there will be changes required once the system goes into full production. Software support is, therefore, essential to ensure that post installs can be supported either remotely or on-site in a timely manner, ideally with the software engineer who coded your machine.

Track Record

The reason you are looking to partner with a bespoke automation machine builder will be there is no standard piece of machinery to suit your application. Although you may see your particular problem as being unique, there is a good chance that a bespoke machine builder has developed some of the processes to a degree in previous projects. It is, therefore, beneficial to identify a partner who has a track record and a sound pedigree of working in multiple sectors. This will allow them to cross-fertilise with their own technical experience and adapt it to suit your project. There will be an infinite number of ways to solve your problem, and a good integrator should be able to provide you with more than one solution. This tailored approach will allow you and the machine builder to create the right fit based specifically on your URS.

Planning

You may have identified an automation partner whose build quality looks good. But how do they manage your project? Delve deep into their quality system to ensure they follow it and review their project management process. Here are some questions that you may want to ask –

• How will they update you through the design and build stages?

o Insist on weekly or bi-weekly updates

• Does their resource plan coincide with your project and other projects they have?

o Cross-check their workload

• How do they record and document meetings, etc?

o Documentation is key in any project

• How do they reduce risk in projects?

o Ensure they run through risk assessment for both safety and functionality. Are there any processes that require proof of concept (POP)?

A good project management process will record everything from design review meetings to project meetings with you, the customer. This approach keeps everyone informed and ensures that there are no hidden surprises.

You should schedule a number of progress visits, ideally with a couple of members of your project team. This can be your maintenance personnel, line operatives or really any project stakeholders who will ultimately have some form of interface with the machine or system.

Machine Acceptance

As part of your URS, it is extremely important that you clearly outline your expectations for when the time comes to carry out the Factory Acceptance Trials (FATs). Some key points are:

• Expected Overall Equipment Effectiveness or OEE.
• Amount of product to be run through the system.
• How you will challenge crucial checks such as vision or test systems.
• The number of trails you will carry out and how long for.
• The rules for the FATs when being carried out. e.g. who will run the machine?

The above list can be added to with as much foolproofing to ensure you run the machine through its paces. You may also consider insisting that the machine builder dry runs the machine (without product) for a period that will prove the mechanical robustness of the machine.

In Conclusion, Things to Look for When Choosing a Systems Integrator

The equipment you are looking to buy is going to be with you for a good number of years and will be a major part of your long-term business success and growth. The relationship between you and your machine builder or systems integrator must be much more than just a purchase order and technical expertise. This has to be a close partnership that has a completely transparent approach, good communication, and openness, which will help you reach your goal of a successful project.

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