checklist for designing a Special Purpose Machine (SPM)
by admin | Jun 21, 2025 | Automation
1. Define Scope & Requirements
- Task Definition: What is the machine supposed to do?
- Output Targets: Required cycle time, parts per hour/day.
- Part Specifications: CAD models, tolerances, material properties.
- Handling Requirements: Manual/automatic load-unload; fixturing.
- Quality Checks: In-line vs. end-of-line inspection needs.
2. Concept & Feasibility
- Process Flow Diagram: Each operation mapped clearly.
- Preliminary Layout: Footprint and space requirements.
- Technology Feasibility: Actuation type, control strategy.
- Cost Estimates: Rough BOM, CAPEX projections.
3. Detailed Engineering Design
- Mechanical Design:
- Structural frame, actuators, sensors.
- FEA for stress validation.
- Electrical/Control Design:
- PLC/PC selection, I/O planning, safety circuits.
- HMI layout and programming logic.
- Tooling & Fixtures:
- Custom jigs, modular clamping systems.
- Pneumatics/Hydraulics:
- Flow diagrams, sizing of valves/cylinders.
4. Build, Prototype & Validate
- Assembly: Tolerancing, alignment, calibration.
- Dry Run: Without parts – motion check, interlocks.
- Pilot Run: With parts – cycle time, defect rate analysis.
- Safety Testing: Guarding, emergency stop, CE/UL compliance.
- Debugging: Iterative refinement of mechanics and software.
5. Installation & Commissioning
- FAT (Factory Acceptance Test): Verify against spec.
- Site Prep: Utilities, anchoring, logistics.
- Installation: Assembly, testing at customer site.
- SAT (Site Acceptance Test): Production-level validation.
- Training: Operators, maintenance staff.
6. Documentation & Support
- Manuals: Operation, troubleshooting, preventive maintenance.
- Software Backup: PLC/HMI code and configuration.
- Spares List: BOM, vendor details, lead times.
- Warranty & Support Terms: SLA and contact protocols.
7. Continuous Improvement
- OEE Monitoring: Track availability, performance, quality.
- Feedback Loop: User input, failure reports, updates.
- Upgrade Options: Provision for future enhancements.