Automation with AGR: Frequently Asked Questions

This might be a difficult question to answer with a succinct answer because it is based on your specific company’s abilities and automation needs. Some of the answer comes down to evaluating your ROI and ROA on the equipment but raises other questions.

What is the product life cycle? What is the value of the end product? What is the anticipated production speed?  Is it worth developing a less capable machine and purchasing redundant machines?

The answer to these questions points to the product life cycle anticipation and the ROI period. In short, do you need the machine to last 5 years or 30 years? There is a difference in materials and construction methods depending on the answer to these questions.

At AGR, we provide detailed, reliable quotes by thoroughly evaluating your application. Our proposals are designed to meet your core objectives and business goals.

This thorough process may take a little longer, but it saves time in the end by ensuring solid performance without guesswork.

In the last decade, Industry 4.0 concepts have enveloped the automation industry, with the intent of connecting all aspects of the business, from the factory floor to the business system and up and down the value chain, from vendors to customers. The overall expected result of this integration is the visibility of information and more efficient production.

Part of the need to implement Industry 4.0 is to be able to read not only KPIs (key performance indicators) of the machine and processes but also the machine or process system health. IIoT (Industrial Internet of Things) information, which might include the need to add strategic sensors to the machine or process, provides insights into the KPIs and machine or process system health.

Pulling this data from the factory floor and storing it in a repository of sorts provides a platform for data analytics, including using AI to look at this historical information. Information such as anomalies, bottlenecks, slowdowns, etc., are information that can be extracted from this data. Applying the learning from the analytics is a key way to continue to optimize the production machinery.

Yes! AGR’s facility encompasses a comprehensive array of departments, each meticulously catering to the construction of your assembly machine.

Besides our own paint shop, we also have welding, modern machining, electrical, quality inspection, and of course, R&D, engineering, programming, and applications departments. Everything you need under one roof! Take a virtual tour.

To check if your vibratory controller or feedback sensor is current or in need of an upgrade, please visit our Vibratory Controller & Sensor Obsolescence Chart. The chart will provide a quick reference to see the status of your parts.

If you’d like a detailed assessment or assistance in upgrading your parts, feel free to request a parts assessment, and our team will be happy to assist you!

You are not alone in this concern. The areas for consideration surround your organization’s abilities to have the skills and support needed to bring the automation in-house. 

To start this process there is a potential need for in-house R&D testing of process testing for discrete aspects of the automation. If so, the next stage would be to do manual assembly operations of your product, while keeping in mind assembly scaling from pilot to full-scale automation when designing product fixtures.

Depending on the number of SKUs in your product or product families, you may need to consider flexible manufacturing.

The considerations are two-fold. It would be best to first consider where your company is along the automation roadmap. Is your production levels low enough that manual production methods satisfy the production quantities? If you have outgrown manual operations, do you need to consider a semi-automatic machine for a medium-level of production quantities? 

At this stage, there may be a need for the added functionality that robotic cells would satisfy. When your production needs surpass these stages, high-throughput, automated assembly is the next stage. While at this highest point, it is also important to maintain the highest OEE possible by monitoring and assessing machine optimization.

One of the biggest stumbling blocks we see for customers looking to bring on automation is internal company skills. A company that is implementing automation systems will require the appropriate level of mechanical and control systems engineering, technicians, and of importance, qualified and trained operators.

There also must be a commitment to spare parts inventory, quality assessment of raw material along with raw material product consistency.

In the past couple of decades, the need to satisfy large demands at an accelerated pace has had manufacturers jump from product concept to full-scale production.

While that method has had some successes, our recent experiences with customers have found that a “de-risking” path to full-scale automation be taken. Taking it in small bites and breaking the automation down to discrete prototypes and pilot production can reduce the risk.

Developing the process and method at each stage of the automated process will help deliver a higher confidence for full-scale production.

Yes, seven of the nine pillars of Industry 4.0 (autonomous robotics, and 3D printing excluded) are essential elements needed to provide a complete remote support program. The artificial intelligence used is comprised of the IIoT sensor network, modeling and simulation, and big data analytics, all of which are leveraged for remote monitoring to check in on how the machine is performing and, as issues are experienced, a preventative maintenance trip can be built to respond to the issues discovered during the remote monitoring sessions.

Absolutely. At AGR, we tailor our automation design to align with your product’s lifecycle, taking into consideration your current phase and future growth. Our solutions are scalable, ensuring they evolve with your needs, from initial production to full-scale manufacturing. Read more about lifecycle stages >>

We provide both initial and ongoing training, including onsite sessions, to ensure your team is fully equipped to maintain high OEE and optimal machine performance. Our onsite training is especially beneficial during employee turnovers or promotions, ensuring continuity and efficiency. Unlike smaller competitors, AGR is committed to supporting your team with the knowledge and skills they need to keep your operations running smoothly. More about onsite training >>

A lot of the small competitors come in at a lower price because they have low overhead but may not have the people and skill level to provide support through the life of the machine. We hear this a lot when a customer is down, they are faced with a slow response time. However, AGR has been entrenched in assembly automation for over 80 years, with the resources and skills to follow you along your product plans.