Running a manufacturing operation smoothly is not easy. One little hiccup in your automated systems and things can come to a halt very quickly, costing the company time and money.
That’s when industrial automation support comes in. But how do you know if it’s the right time to bring in the experts? And more importantly, where do you find the support you need?
In this article, I will break down the common support services types, benefits, when to hire support, overall costs, where to find support, and so much more.
What is industrial automation?
Industrial automation refers to the tools, technologies, and equipment that control and monitor automated processes with minimal human intervention. By automating dangerous, complex, or repetitive tasks, industrial automation makes operations more efficient, productive, and reliable.
These systems often include various components like:
- Control Systems: Manage machinery and processes with devices like PLCs and DCS.
- Sensors and Actuators: Sensors collect data while the actuators perform actions based on that data collected.
- Human Machine Interface (HMI): Lets operators interact with the automated system, providing real-time data feedback and operational control.
- Robotics: Industrial robots handle repetitive manufacturing tasks, such as material handling, welding, pick-and-place operations, visual inspection, and more.
- SCADA: Monitors and controls large-scale operations by gathering data from various sensors.
- Industrial Networks: Ensures seamless communication between all automation systems and components.
- Software And Analytics: Control systems will analyze data to optimize performance and predict failures.
As sophisticated as these systems may seem, they are vulnerable to a great list of problems, just like any other piece of machinery. This is why any automation system needs a reliable support team.
What is industrial automation support?
It is like having a dedicated team of industrial experts ready on standby, waiting to keep your machinery and systems up and running.
Imagine your factory’s robots, conveyors, and control systems needing regular check-ups, just like a car. These experts handle everything from routine maintenance, installation and line updates, to supporting current production.
If a company uses contract industrial automation support, they will expect to see improvements in inefficient production lines, and reduced downtime. The contract support engineers are there to monitor your systems, catch problems early, and make sure everything operates to its maximum potential.
What are some common types of industrial automation support?
Companies handle various tasks to keep automation systems in the best shape possible. In industrial automation, these tasks usually include to following listed below:
Preventative Maintenance Support:
Preventative maintenance is like giving your equipment a regular system review. The idea is to have the contract engineer perform routine inspections and identify minor fixes to catch future problems before they turn into major issues or downtime.
This might include tasks like cleaning, lubricating parts, changing consumables, and making small adjustments. By monitoring these regular maintenance activities, you will avoid unexpected failures and extend the life of your automation machinery.
Production Support:
The engineers who work on this type of support will make sure your automation systems and equipment are in their best working conditions. Often times companies do not have the proper workforce who are technically skilled to operate automation equipment.
Until they have the time to hire the right person for the job, they often use contractors to fill those roles until the find a full-time employee to run the equipment.
This happens when companies are new to an area, growing in size, or even trying to reduce labor costs by using one person who can do the job of three people.
Emergency Support:
Emergency maintenance is the “firefighting” part of industrial automation support. When a piece of equipment fails unexpectedly, you need an expert team or person who can respond quickly to get your manufacturing process running again.
These types of services are often more expensive because the customers often need support within 24 hours.
Cycle Time Support:
This type of support is for when companies need performance improvements in their equipment to meet production demands. A company will request cycle time support to keep their automation equipment running as efficiently as possible.
Many times, using outside resources is the best and most efficient way to do this because your current staff may not be able to provide the required support needed to make these types of production improvements.
Training Support:
Training employees is the key to keeping your automated systems running smoothly. Hands-on training sessions assist your team in getting comfortable with the equipment, learning best practices, and handling routine maintenance perfectly.
These sessions are more than just reading the user manuals, they are interactive and practical learning classes, from answering quick questions to troubleshooting the most difficult problems. Your team can receive on-site training from one day to a year or more, depending on the questions or issues that arise.
System Integration Support:
System integration services make sure that all components of your automation system are installed properly and work seamlessly together. This means supporting the installation of new equipment or upgrading existing systems.
These contract engineers will ensure system compatibility and troubleshoot any integration issues that arise with the automation equipment.
The benefits of industrial automation support.
Having a reliable support team is a must for any business, but even more so for one that relies on complicated automation systems. Below, I list many key benefits that make it a necessity for any manufacturing company.
Minimized Downtime: Downtime can be the worst enemy of any industrial manufacturing operation. Luckily, if a company has the right industrial automation support, they can decrease downtime by keeping the equipment up and running. Regularly checking the systems means fewer unexpected breakdowns.
Increased Productivity: When your equipment runs smoothly, your whole operation speeds up. Well-maintained machines work at peak performance, pushing out products faster and more efficiently with the right team of contract professionals.
Cost Savings: A little investment in supporting maintenance can save you a bunch in the long run. Preventative and predictive maintenance helps you dodge costly emergency repairs and equipment replacements.
Extended Equipment Lifespan: Regularly supporting your machines means they last longer. Addressing wear and tear early on keeps them running like new, which gives you more bang for your buck and delays the need for expensive new repair purchases.
Increased Safety: Safety first! Regular maintenance includes safety checks and updates, which reduces the risk of accidents. Reliable equipment means a safer workplace, so everyone goes home in one piece and keeps you compliant with regulations.
Better Quality Control: Consistency is key in production. Reliable machines ensure stable processes and better quality control. Fewer disruptions mean fewer defects, which helps ensure your products meet high standards every time.
Access to Expertise: Having a dedicated assistance team means you’ve got experts on call. These pros know your systems inside out and can troubleshoot issues, offer insights, and implement best practices to keep your operations smooth.
Scalability: Growing your business? No problem. A professional assistance team helps you scale up efficiently, whether you’re expanding your production line or upgrading systems. They’ve got the know-how to handle increased demand and more complex operations.
When is the right time to hire a support team or professional?
Is it time to bring in expert labor support? Below, I list the six signs that it’s time to hire professional support.
- Frequent Downtime: Are the automation machines constantly breaking down? Regular breakdowns can cripple productivity, in turn creating an inefficient production line. If your company has an automation support team to keep your equipment up and running smoothly, this minimizes costly stops or breakdowns and keeps your line as efficient as possible.
- Increased Production Demands: Is your business growing, and your production demands are skyrocketing? As companies scale up, so do the complexities of an automation system. Contract automation support services can help a company handle the increased workload while your own employees keep everything else on its production schedule.
- Lack Of In-House Expertise: Is your company feeling out of your depth of knowledge with complex automation systems? If your team lacks the technical know-how, it’s time you find engineering experts. Having a dedicated automation support team can ensure your systems are in the hands of top-notch engineering professionals.
- High Maintenance Costs: Are maintenance, service, and spare part bills continuously piling up? Constantly troubleshooting and repairing equipment can drain a company’s maintenance budget fast. With an automation support team, companies can implement detailed preventative maintenance strategies and plan to catch problems before they become costly repairs, replacements, or major downtime in manufacturing.
- Upgrading Or Expanding Systems: If a company is planning to upgrade, perform a KIT change, or expand current automation systems, then bringing in industrial engineering contractors might be a great solution. New technologies and assembly line expansions need seamless integration, and contractors can manage this transition smoothly, ensuring optimal performance without major disruptions to the current production process.
- Compliance And Safety Requirements: Worried about meeting stricter compliance and safety regulations? Using a support team ensures your automation systems are up to the required process standards, keeping your employees safe and your equipment compliant with industry safety regulations.
How to find the right industrial support team?
Finding the right industrial automation contractor can make all the difference in keeping your manufacturing operations running smoothly. Here are some tips below to help choose the best team (or individual) for your contracting needs:
1. Look for Experience:
Experience is key when it comes to industrial automation support. You want a person that has a proven track record in your specific industry. The more experience they have, most likely, the better they’ll handle your specific industry-related issues that arise.
2. Check Their Reputation:
A good reputation is a strong indicator of their ability to provide reliable automation services. Look for reviews and testimonials from other clients on Google or have them provide you with references. Make sure to follow up with references to understand how they perform in real-world situations.
3. Assess Their Availability:
Your industrial support team needs to be available when you need them. This includes regular maintenance as well as when emergencies occur. Make sure they offer great assistance quickly if your operations are running around the clock. It’s important to know they can provide support if and when something goes wrong (because it will!).
4. Evaluate Their Technical Skills:
Make sure they have the technical expertise to handle your specific automation equipment and systems. This includes understanding the latest automation technologies, having the ability to troubleshoot complex issues, and providing basic technical support services. Don’t forget to ask about certifications and training to make sure they are up to date with basic industry standards.
5. Understand Their Pricing:
While cost shouldn’t be the only factor when determining your automation support requirements, it’s still an important consideration. Make sure you understand their pricing structure and what exactly is included in their automation services. More importantly, look for a team that offers transparent pricing and can provide a good balance between cost and quality of service.
If you’re not ready to take on a permanent employee, contract engineering services can be an excellent alternative. You can find engineering professionals who can deliver the automation solutions you need, but you don’t have to commit to a full-time employee until the company is ready to grow.
How much does industrial automation support cost?
The cost can vary widely based on several key factors that I list below. Let’s examine what influences pricing, and I will try to give you an idea of what to expect.
Factors Influencing Costs:
The type of service you need is the main factor driving the cost of support, but there are other things you should consider, such as:
- Scope Of Services
- Frequency Of Support
- Type Of Equipment
- Level Of Expertise
- Response Time
- Location
- Contract Type
Typical Cost Estimates:
I have listed a few different estimate types to give you an idea of how much industrial automation support services might cost:
- Maintenance And Engineering Services: For small to mid-sized projects, basic preventative maintenance might range from $8,000 to $15,000 per month, depending on the number of machines and complexity.
- Comprehensive Support Packages: For larger operations needing extensive automation support, including 24/7 emergency response and regular updates, costs can range from $10,000 to $20,000 monthly or more.
- Hourly Rates: If you opt for on-demand services, expect hourly rates from $75 to $200, depending on the engineer or technician’s expertise and the type of work required.
- Installation Support Or System Upgrades: Minor updates might be included in regular maintenance, but major upgrades, KIT changes, or custom solutions can cost between $10,000 and $50,000 or more per month.
- Emergency Support: Emergency services, especially outside normal working hours, can be significantly pricier. These might start at $200 per call-out and increase depending on the repair’s duration and complexity.
Industrial automation support on JOINER Services!
A reliable support team (or individual) might just be the solution to fix your industrial automation woes, but where do you find a professional you can count on? Look to JOINER Services as the go-to engineering services platform for companies that need the best contract engineers in the country.
Join for free today and start browsing hundreds of engineering profiles!
FREQUENTLY ASKED QUESTIONS
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