This curriculum spans the technical, operational, and organisational considerations of integrating automation into established lean and Six Sigma environments, comparable in scope to a multi-phase operational excellence initiative involving cross-functional process redesign, systems integration, and ongoing governance.
Module 1: Defining Automation Scope within Lean and Six Sigma Frameworks
- Selecting value stream segments where automation reduces non-value-added time without masking underlying process instability
- Aligning automation initiatives with DMAIC phase outcomes, particularly ensuring control phase sustainability through automated monitoring
- Deciding whether to automate a process step pre- or post-5S implementation based on workspace standardization maturity
- Evaluating whether automation supports takt time alignment or introduces overproduction risk in pull-based systems
- Integrating automation feasibility assessments into process failure mode and effects analysis (PFMEA) for high-risk operations
- Using spaghetti diagrams to identify repetitive motion waste suitable for robotic process automation (RPA) intervention
Module 2: Assessing Process Maturity for Automation Readiness
- Determining if process stability metrics (e.g., control chart behavior, Cp/Cpk >1.33) justify automation investment
- Conducting baseline cycle time studies to quantify potential gains before introducing automation latency or setup overhead
- Deciding whether to stabilize a process manually using standard work before automating inconsistent operator-dependent steps
- Using process capability data to prioritize automation in high-variation, high-defect areas versus low-hanging efficiency wins
- Assessing changeover frequency to determine if flexible automation or quick die change (SMED) should precede full automation
- Mapping process inputs using fishbone diagrams to isolate automatable variables from human judgment-dependent factors
Module 3: Technology Selection and Integration Architecture
- Choosing between embedded PLCs and external middleware for data exchange in legacy machine environments
- Designing OPC-UA or MQTT protocols for real-time data flow between shop floor automation and MES systems
- Deciding whether robotic process automation (RPA) bots should run on user desktops or centralized servers based on security and uptime needs
- Integrating vision systems with existing barcode scanners to automate quality inspection without disrupting line speed
- Configuring edge computing nodes to preprocess sensor data before sending to cloud analytics platforms
- Selecting low-code automation platforms based on API compatibility with existing ERP and CMMS systems
Module 4: Change Management and Human Workflow Redesign
- Redefining operator roles from manual execution to monitoring and exception handling in semi-automated cells
- Designing shift handover procedures that include automated performance dashboards and anomaly logs
- Implementing layered process audits to verify that automated controls do not erode operator engagement
- Adjusting performance metrics to reward problem detection and root cause analysis over output volume post-automation
- Developing escalation protocols for automated system failures requiring human intervention
- Conducting time studies to reallocate labor hours from automated tasks to kaizen improvement activities
Module 5: Data Governance and Performance Monitoring
- Defining data ownership and access rights for automated process logs across IT, operations, and quality teams
- Configuring automated alerts for out-of-control conditions while minimizing false positives that lead to alarm fatigue
- Calibrating automated measurement systems (e.g., CMMs) and validating against manual gage R&R studies
- Setting thresholds for automated process adjustments (e.g., SPC-triggered parameter changes) to avoid overcontrol
- Archiving raw automation data to support future root cause investigations during customer audits
- Using automated Pareto reports to prioritize recurring defects without manual data aggregation
Module 6: Risk Mitigation and Contingency Planning
- Designing manual override capabilities for automated lines to maintain production during system failures
- Conducting FMEA on automated systems to identify single points of failure in control logic or power supply
- Establishing backup procedures for RPA bots when target applications change UI structure unexpectedly
- Testing rollback procedures for firmware updates on industrial robots to prevent extended downtime
- Validating automated safety interlocks (e.g., light curtains, e-stops) during changeovers involving human access
- Assessing cybersecurity risks in connected automation systems and segmenting OT networks accordingly
Module 7: Sustaining Improvements and Scaling Automation
- Embedding automated KPIs into daily management review boards to maintain visibility and accountability
- Updating control plans to include automated process checks and sensor calibration schedules
- Standardizing automation templates (e.g., robot programs, RPA scripts) for replication across similar processes
- Conducting periodic automation audits to identify degraded performance or workarounds bypassing controls
- Using digital twins to simulate automation changes before physical implementation in high-risk environments
- Establishing a center of excellence to govern automation standards, tool selection, and knowledge transfer
Module 8: Economic Evaluation and Lifecycle Management
- Calculating total cost of ownership (TCO) for automation, including maintenance, energy, and software licensing
- Using net present value (NPV) analysis to compare automation ROI against alternative lean improvement investments
- Setting depreciation schedules for automation equipment aligned with technological obsolescence risk
- Planning for end-of-life migration of legacy automation systems with proprietary protocols
- Tracking unplanned downtime costs of automated systems to validate business case assumptions
- Reassessing automation justification when product mix changes reduce volume below breakeven thresholds
