Process Development - Midwest Engineered Systems

Teaming Up With Our Customers to Link the Divide Between Design and Production

Midwest Engineered Systems has been developing automation systems for over 30 years for a number of industries and production processes. This diversity of experience provides MWES with the ability to arrive at unique process solutions that translate to greater throughput and quality without sacrificing uptime and dependability. While our knowledge and experience may be broad, our success comes from singularly focusing on our customer’s goals and requirements.

automated robot palletizing conveyor with fanucOur approach to automation process development is to first evaluate the firm’s current production operation and understand the company’s process needs. MWES further evaluates the manufacturing system’s speed, quality, and other process metrics. While the former comes from discussions with the customer and detailed analysis of the request for quote (RFQ), the latter usually starts with an on-site visit with our automation engineers to understand, in-person, how the current process works at the floor level, as well as a detailed collection of information and materials.

As a true partner in the automation process, we work with our customers to establish attainable requirements, goals, and risk thresholds for a potential automation system. Midwest Engineered Systems then takes these specifications and develops a new prototype production automation process to address them. Our engineers work do develop innovative solutions that preference the automation industry’s best products and when an appropriate system is unavailable, engineer custom automation machinery in-house to solve challenges.

Typically, 2-3 options are developed by our engineering team for the project. These are presented to the customer for evaluation. Simulations of the system’s performance can be built to provide highly accurate estimations of its potential performance. While it is our preference to rely on proven operations and hardware, newer processes can be tested and analyzed using our proof of principle process to determine if the operations meet the necessary requirements such as up-time, through-put rates, quality, and process capability requirement.

After arriving at a consensus with the customer, Midwest Engineered Systems moves toward the development of a turnkey production line that both MWES and the customer feels confident in its operation and performance. Then a formal fixed bid is submitted to the customer that breaks down the project cost and a detailed overview of materials used, project timelines and agreed upon machine performance. Then it is up to the customer to accept the bid and MWES moves to build the automation system.

Contact Midwest Engineered Systems today to learn more about our process development experience and capabilities!

Process Development Can Improve Manufacturing By:

  • Reducing product cost
  • Reducing equipment cost
  • Improving process quality
  • Increasing process speeds and consistency
  • Improving overall equipment performance

Process Improvements on Existing Systems

Many times, a production automation system does not need to be completely replaced, but a detailed analysis of the system’s performance can yield cost-effective changes that can boost its performance. Midwest Engineered Systems can provide production line analysis services using its process development experience to help determine where efficiencies can be found. Process Improvements include evaluation of current equipment capability and determination for implantation of new sensors, controls, and methods to improve manufacturing.

System Controls Updates

plc panelModern production systems come with improvements like finer, more efficient process control and data acquisition that leads to better overall performance. These improvements can usually be had by legacy systems through a carefully considered retrofit roadmap. Process improvements are offered to optimize your current equipment to improve functionality and to increase the life of your system. These improvements typically involve custom developed software and current controls hardware that improves tasks and processes. MWES offers these services as well. Our application engineers are able to guide customers through the landscape of new technologies to arrive at a plan to upgrade a production system to the latest in capabilities.

Benefits to Process Improvement and Controls Updates:

  • Increased Return-on-Investment
  • Lower up-front investment vs. buying new
  • Improved part throughput
  • Increased quality

Process Development Workflow

1EVALUATIONSTEPEvaluate and question the current operation or process assumptions. This is the beginning of the product process plan. 2REQUIREMENTSSTEPProduction and quality requirements are determined and identified. The risk is determined and a risk threshold is established. 3RESEARCHSTEPAreas of risk beyond threshold are identified. Research and brainstorm process methods. The outcome should result in 2-3 testing options. 4TESTINGSTEPProcess simulation testing is conducted on the chosen concept to ensure the desired results are met. 5ANALYSISSTEPAfter testing is completed, report the data to analyze the production and quality capability. 6RESULTSSTEPThe final report is an evaluation of the test performance results. This helps to determine whether to proceed to design & build or retest another concept.

Read the Free White Paper

Bridging the Gap Between Design & Manufacturing:
A Guide to Process Development

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