You're balancing automation and manual labor in manufacturing. How do you ensure a smooth transition?

1. Assessment: Evaluate current processes to identify tasks suitable for automation and those requiring human skills. 2. Planning: Develop a clear implementation plan, including timelines, budget, and resource allocation. 3. Training: Invest in training programs to upskill workers for new roles in an automated environment. 4. Pilot Programs: Start with pilot projects to test automation in a controlled setting. 5. Integration: Gradually integrate automated systems, allowing time for adjustment. 6. Feedback: Collect feedback from employees to address concerns and improve processes. 7. Maintenance: Ensure regular maintenance of automated systems to prevent downtime. 8. Communication: Maintain open communication to keep all stakeholders.

In my view there is no question of balance, rather its its mindset change to move from manual-labor to automation, evenif with corner thought that on cost prespetive front especially labor abundant Set-ups. Its a change where automation will enable do more repetative work with type of "Basic skill job" and Manual-Labor will focus to improve productivity on "highly skilled job".

In my view the strategy will vary from country to country. Social consideration will play a very important role in deciding such strategy. While repetitive, high precision, highly hazardous activities can be automated. But availability of human resource, it’s cost, societal need like employment, population and its age will define the path forward. It is not simple vanilla…. Industry Leaders have to consciously apply their choice between “ wealth creation” and “nation building”.

I like to use agile methodology during this step, as it allows for flexibility and iterative progress. Agile helps break down the project into manageable tasks, enabling continuous improvement and quick adaptation to changes. This approach ensures we can respond promptly to any challenges that arise. Analyzing actions needed in different scenarios is also crucial. By considering various potential outcomes and preparing for them, we can mitigate risks and ensure a smoother transition. This proactive approach helps identify potential bottlenecks and address them before they become significant issues.

Training is a must for any change. From the planning day to the final commissioning day and for a set period of extended time till every employee in the "changed" work environment is familiar with the change. When it comes to automation the safety of the employees who worked in the functioning area and the supervisory staff should know the working and safety of the new introductions. Training also has to be towards the acceptance of the automation into their working environment. This will have to be more directed towards behavioural or attitudinal change towards accepting modernization. The concern will be towards loss of opportunity and risk of employee reduction.

Yes.... agree with your listed words, linked to the Training your staff and continuously systems update accordingly. Follow new updates and cover maximum requirements according to the manufacturing process.

There is no easy path to this task at all! The reality is automation in all forms is headed and is already here. Cultivating a culture with a mix of new people trained in automation and current personnel having all the in depth knowledge of the business is key. Showing current personnel how to use the automation hands on by the person who is charging the forward with automation is key. Tailoring training to current staff to show them how it will make their jobs more efficient and at the same time illustrating all the other things they can do for the business in the absents of what they were doing. Job security is the number one factor in the acceptance of automation.

To effectively monitor an automation project, I track each Overall Equipment Effectiveness (OEE) component throughout the project, especially post-implementation. This enables comprehensive monitoring of project quality and allows for necessary adjustments, additional training, and other actions. Key steps include defining clear KPIs, implementing regular data collection, and utilizing real-time monitoring systems for continuous oversight. Conduct periodic reviews, collect employee feedback, and be prepared to make adjustments based on data. Perform post-implementation audits and encourage a culture of continuous improvement. This approach ensures successful project execution and long-term success.

Gathering KPI thru automation based on human behavior in the work place is extremely important. Don't let them know your collecting it. Use the knowledge, make changes and watch the data. If employees know the information is being collected it will alter behavior in a different way then may be intended. Information that is relevant and reliable and understanding the strengths and weaknesses of the data is a mangers advantage. Don't do to much at one time, the data and your changes will be extremely tough to track and react to.

The therbligs help to break down any work into a sequence of activity elements (there are 17). Typically, per MOST, there tend to standard combinations of these activity elements that are performed. Each therblig presents challenges to a dumb robot that will need sensory and decision making capabilities embedded into its control software. While you could jump right into RTM (Robot Time Measurement) to go all out on robotization, I advocate back to basics —— use Operations Analysis and 5W1H questioning and EVRSSA thinking to eliminate the 3Ms out of the work system. That is, simplify it to the maximum for it to be done manually …. THEN seek to do a DFRA analysis to replace the operator with the robot … I could elaborate if u want …?

Expect problems. Never underestimate the ability of an operator to listen very carefully to all your instructions and then proceed to do exactly what they have always done. Don't go nuts when this happens. It is crucial to figure out these kinds of problems. It is very important that problems get reported, or you will never know the cause. Important to over and over teach operators the right thing to do and do it. Otherwise you can be banging your head against the wall trying to figure out why the same problem keeps occurring when you thought you addressed the problem, corrected it, and then find, on further inspection, nothing changed.