What are the Risks of Bespoke Automation?

November 2019

The word automation has really only been used in the wider world since around 1947 when Ford started to establish its automation future and open an automation department. Before this, there was fear of the risk of bespoke automation.

With this really being the start of things to come with regards to manufacturing, Ford was, in fact, developing an automated solution to suit their own needs and tailored solutions to suit their manufacturing processes, which could be classed as bespoke systems.

As automation has advanced, and no more so rapidly than it is in today’s world, there are many standard automation solutions out there that help us carry out our daily, personal and working lives in a much simpler and quicker manner. From washing machines in our houses to fully automated solutions in production plants, with the common purpose being to carry out the task as efficiently as possible and produce high-quality results.

Within manufacturing, “off the shelf “automation allows organisations to utilise tried and proven solutions for their process. From whisky bottling lines to carton erectors through to warehouse automation, there are standard solutions to suit most needs.

SO WHAT’S YOUR OPTION IF YOU CAN’T FIND A STANDARD SOLUTION?

Away from “standard automation” there is often the need to have a system custom built to suit. This is “bespoke automation”, a solution designed and built to suit your exact needs.

IS BESPOKE AUTOMATION MORE EXPENSIVE?

The terms “custom” and “bespoke” would indicate that there is a premium to be paid if going down this route, just as would happen if you were to have a motorbike designed and built to your defined specification.

Typically, this is the same for a bespoke automation solution. Within the scope of supply, there would be a design and development cost associated with the project. As it is a one-off solution, manufacturing such a system would be less cost-effective (no mass production) than that of a standard one,  as many parts would be a one-off.

There are instances where bespoke automation could be more cost-effective. With standard automation, a process or solution may have been refined over the years to suit a multitude of applications and, therefore, may have many features that you do not require. With bespoke automation, these features can be minimised and potentially result in a lower cost.

DOES BESPOKE AUTOMATION CARRY A GREATER RISK?

As soon as something has to be designed and developed from scratch, the risk to the success of the project from functionality as well as a commercial point of view increases. The way to help mitigate the risks is to ensure there is a clear vision and understanding of what the final solution has to do.

DEFINE YOUR REQUIREMENTS

A well-defined User Requirement Specification (URS) is crucial. This document lays the ground rules for your solution. It provides your machine builder with all the information relating to your process, from how raw materials are to be presented to the machine to how the product or assembly is to be inspected and even down to defining an assembly sequence. What this document doesn’t do is define how the machine will be designed. This comes down to the machine builder.

RISK REDUCTION STRATEGY

Presumably, the reason for looking at a bespoke piece of kit is because there is nothing out there as standard to do what is required. This would suggest that certain aspects of your process may pose a higher risk. This could be down to the assembly process, a packaging issue or even how the final product is inspected. Clearly defining what needs to be developed at the start of your journey can prove to be an invaluable approach. Carrying out Proof of Concept (POC) trials and even manufacturing complete machines to develop the process is sometimes needed. On the face of it, this can be costly, but in the long term, it can be the difference between the success and failure of the project.

PARTNERSHIPS – HOW TO SELECT THEM?

• Bespoke automation requires an open and transparent partnership between all the stakeholders involved in the process. The selection of the automation machine builder requires very close due diligence to ensure they are the right fit for you and your projects. Perhaps they have worked in your industry and have relevant experience, or perhaps what you require is something completely new, in which case it is important to see the approach the machine builder uses for solving problems.

• Look at how the company manages projects from risk as well as a project management point of view. From a project point of view, look to see how they manage problems when they arise in the cycle. The very nature of bespoke automation means there will be problems encountered; it’s making sure that everyone is aware of the problems and a plan is put in place to make sure the problem is resolved without impacting the project timelines. Internal resources and capabilities are also important. If the machine builder relies on external resources in order to carry out their projects, then this could cause issues during the duration of the projects. As an example, if the machine builder relies on outsourcing software, this may cause an issue during various stages of the project if they suddenly don’t become available. Ensure your chosen machine builder has the appropriate in-house resources to meet your needs.

Bespoke automation only becomes a high risk if mismanaged.

IN SUMMARY

If possible and to reduce risks as far as possible, buying off-the-shelf automation is by far the best way to go. If this is not an option, then having a well-defined URS and a strategy and carefully selecting the correct partner can help ensure that any bespoke automation project that you deal with is handled as seamlessly as possible.

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Read more about our automation here…

• Benefits of Automation
• The Benefits of Machine Vision Technology
• Robots & Cobots – What is the Difference?
• Robotic Automation
• What is a URS? Why is it Important?
• Cost of Industrial Automation
• Advantages & Disadvantages of Robotic Automation

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