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.