Key Takeaways
- Manufacturers should establish measurable performance requirements before an automated assembly machine is built.
- Testing should account for product quality, production speed, part variation, and the conditions the machine will encounter in operation.
- Inspection systems and reject handling can help identify problems before defective assemblies move further down the line.
- Operator access, troubleshooting, and maintenance should be considered alongside production performance.
- Early collaboration between manufacturers and machine builders helps define expectations and identify potential issues before installation.
Selecting automated assembly machinery requires a clear understanding of production targets, quality requirements, and the conditions the equipment will encounter on the factory floor. Manufacturers need to know whether a machine can maintain consistent output, handle normal component variations, and meet the specifications of the finished product.These details are especially important when developing custom assembly machines. A system may perform well during an initial demonstration but encounter different challenges during extended production, when components vary, adjustments become necessary, or individual stations require attention.Defining performance expectations early gives the manufacturer and machine builder a shared understanding of what the equipment needs to accomplish. It also provides a practical basis for evaluating the finished system before it enters production.
Define What the Assembly Machine Needs to Deliver
The first step is to establish clear requirements for the product and the assembly process. These should reflect actual production needs rather than an isolated target for machine speed.
For example, a manufacturer may need to assemble several components in sequence, verify that each connection is secure, and reject products that fail inspection. The machine must complete these tasks within the required production cycle while maintaining the necessary quality standards.
Several factors should be defined during planning:
- Production rate:Establish the expected output under agreed operating conditions, including whether the target must be sustained over an extended run.
- Product quality:Identify critical dimensions, assembly conditions, functional requirements, and acceptable defect levels.
- Component variation:Determine how normal differences in part dimensions, orientation, or material characteristics could affect machine performance.
- Product changes:Identify whether the machine must accommodate different product versions, sizes, or configurations.
- Operating requirements:Consider operator interaction, maintenance access, troubleshooting, and the expected production schedule.
These requirements help shape the machine design and provide criteria for evaluating its performance. The National Institute of Standards and Technology emphasizes the importance of performance measurement in manufacturing system design and analysis.ยน Establishing meaningful measures before a project begins helps teams assess whether the proposed system meets its intended goals.
Test the Machine Under Realistic Conditions
Once a machine has been assembled, testing helps determine whether its mechanical systems, controls, and integrated processes perform as intended.
Testing should reflect the products and conditions the equipment will encounter in production. Depending on the application, this may involve running representative components, verifying assembly sequences, evaluating operating speeds, and checking how the machine responds when a part is missing or incorrectly positioned.
The materials used during testing matter, too. Components produced under actual manufacturing conditions may have small variations in dimensions or orientation. Testing with representative parts helps reveal whether the machine can accommodate those variations within the agreed specifications.
Manufacturers and machine builders should also establish how results will be evaluated. A successful test should demonstrate that the machine meets defined requirements, with clear procedures for documenting issues and resolving discrepancies.
Where formal factory and site acceptance testing is included in the project, the International Society of Automation's ISA-105 series provides guidance on testing and commissioning automation systems.² The specific testing plan should reflect the machine, the application, and the requirements agreed upon by the project team.
Evaluate Inspection and Reject Handling
Production speed is only one part of machine performance. Manufacturers also need to understand how the system identifies assembly problems and responds when a product does not meet specifications.
Automated inspection can be integrated into assembly machinery to check product characteristics during or after assembly. Depending on the application, vision systems may verify component presence, orientation, dimensions, markings, or other required features. Other integrated tests can evaluate functions such as seal integrity or leakage.
The inspection method should match the type of defect the system needs to detect. Teams should establish which product characteristics require verification, how inspection results will be evaluated, and what happens when a product fails.
Reject handling is part of that process. The machine should distinguish products that pass inspection from those that require removal or further review. Testing these sequences helps verify that a failed inspection does not allow an unacceptable product to continue through the line unnoticed.
Norwalt offers vision inspection systems that can be integrated into automated production equipment. Considering inspection requirements during machine development helps align assembly operations with the checks needed to verify finished products.
Consider Usability and Maintenance Before Installation
A machine also needs to work for the people responsible for operating and maintaining it. Difficult access to adjustment points, unclear fault messages, or complicated recovery procedures can make routine production problems harder to resolve.
During testing and review, manufacturers should consider whether operators can understand the controls, access necessary components, and follow the intended procedures. Maintenance teams should be able to reach serviceable parts and identify common sources of faults without unnecessary disruption.
Troubleshooting deserves particular attention. When a machine stops, operators need a practical way to identify what happened, correct the issue, and resume production safely. The recovery process can influence how much usable production time the equipment delivers over a shift.
These considerations should be built into the project requirements and reviewed before installation. Addressing them early helps align the machine's design with the realities of the production floor.
Work With a Machine Builder From Design Through Testing
The most useful performance reviews begin during the engineering process, not after the machine is complete. Early collaboration gives manufacturers and machine builders an opportunity to resolve questions about product handling, assembly methods, inspection requirements, and operating expectations before those decisions become difficult to change.
Norwalt designs and builds custom automated assembly machinery for applications across industries including medical devices, food and beverage, and personal care. Its capabilities span concept development, custom machine design, integrated inspection, robotics, and high-speed assembly systems.
By working with the engineering team to define the product requirements and intended production process, manufacturers can establish a clearer basis for machine development and testing. Norwalt also tests its machines and conducts quality checks before delivery, helping evaluate equipment before it reaches the customer's facility.
Manufacturers planning a new automation project can explore Norwalt's custom assembly machine solutions to learn more about its capabilities or contact the team to discuss a specific application.
Frequently Asked Questions About Assembly Machines
- What should manufacturers test before putting an automated assembly machine into production?
Manufacturers should evaluate whether the machine meets its agreed requirements for production rate, assembly quality, component handling, inspection, and operating performance. Testing should use representative products and include relevant operating conditions. - Why should performance requirements be defined before a machine is built?
Early requirements give the manufacturer and machine builder a shared definition of success. They help guide design decisions and establish criteria for evaluating the finished machine. - How can automated assembly machinery help improve quality control?
Depending on the application, automated assembly machinery can integrate inspection, functional testing, and reject handling into the production sequence. These capabilities help identify products that do not meet established requirements before they proceed further through the process.
References
- National Institute of Standards and Technology, Operations-Driven Performance Measurement for Smart Manufacturing Systems.
- International Society of Automation, ISA-105 Series of Standards