Process Planning and Automation Services

Process planning and automation have been practiced since the early days of manufacturing. Process planning is used to make optimal use of resources to reduce the time to market, improve product quality, increase production efficiency and cut production costs. With increasing competition and reducing demand, it is necessary to automate and optimize various elements of a manufacturing process. Optimal Consulting provides process planning and automation services to many companies in the world.

Though many production scheduling software exist in the market, they are limited to standard production processes only. Besides, they need to be tweaked heavily to work for every company. However, they can be used in conjunction with a customized process automation plan after analysis of the current process.

Process Planning Services Offered by Optimal Consulting

1. Plant layout design and automation

• 2D / 3D layout design
• Simulated factory automation
• Assembly process simulation
• Robotics simulation
• Station layout and optimization
• Simulation-based work instructions

2. Manufacturing process planning

• Process analysis
• Product assembly planning
• Process documentation and report development
• Manufacturing component process planning
• Safety systems planning
• Control systems planning
• Containerization
• Process templates creation

3. Skills / Resource planning

• Material flow simulations
• Resource standardization
• Resource classification
• Resource assemblies
• Parametric search for resources

For almost a decade, we have been helping several international companies design better products, reduce their time to market and improve cost efficiencies. We can help create a custom plan for your production process by utilizing the latest in computer aided process planning (CAPP) / system process planning.

Application of Our Process Planning Services

We possess expertise in the following areas of application:

1. Tooling and fixture development
2. Prototype development
3. Lean manufacturing
4. Construction equipment manufacturing
5. Plant operations

The main aim of our process planning solution is to optimize the production process in order to achieve better efficiency and lower costs. To achieve these and other objectives, it is important to automate various functions in a process. Process automation or automation engineering aids in achieving the goal of optimizing production processes. Based on the nature of a production lifecycle, customized automation services can be implemented. These can also include individual machine automation and complete factory automation (plant automation).

Our Process Automation Services

At Optimal Consulting, we provide the following process automation services, at a high level of functionality and quality.

1. Distributed control services (DCS )
2. Programmable logic controller (PLC) services
3. Automation planning and analysis
4. Software testing and support
5. Plant simulation and 3D modeling
6. SCADA (Supervisory Control And Data Acquisition) services
7. L2 / L3 support
8. Monitoring and analysis support
9. Communication protocol development
10. Engineering tool development
11. PLC selection, programming and commissioning
12. GUI (Graphical user interface) / HMI (Human machine interface) development
13. Development of drivers and OPC servers for field devices
14. Asset management services
15. Real-time application support
16. Conversion and migration of control software

Get the Optimal Consulting Advantage

Though production efficiency and improved quality are the two benefits of process automation / process integration, other advantages include:

• Better inventory management by optimizing flow of materials and people
• Reduced manufacturing planning time by planned distribution of resources
• Reduction of work-in-progress
• Better layout planning, ensuring cost savings
• Accurate assessment, detailed planning and accurate cost estimation
• Improved collaboration and reuse for faster development

Changing economic conditions and demand volatility have changed the way how manufacturing companies work. Our automation tools and automation software help you stay one notch ahead of your competitors and better serve your customers’ needs. Utilizing a mix of computer aided process planning and manual planning, we can help you optimize and improve your production process. With a qualified team of engineers, quality analysts, project managers and business experts, we can help you achieve your business objectives quickly.