Show Menu

Automation Project 11 Steps Cheat Sheet (DRAFT) by [deleted]

Automation Project Sample Plan

This is a draft cheat sheet. It is a work in progress and is not finished yet.

Phase 1: Automation Plan

Existing system operating proced­ures
Highest potential automation areas
Hardwa­re/­sof­tware block diagrams
Field Hardware and sensor requir­ements
Operat­ional documents requir­ements
System implem­ent­ation plan and schedule
System develo­pment, integr­ation, assembly & testing requir­ements
Phased pricing summary
Return on investment analysis

Phase 2: Project Kick-Off Meeting

Review scope of work and clarity integrator and client respon­sib­ilities
Establish a mail and transm­ittal system
Set up a drawing list
Obtain a set of safety requir­ements
Obtain reference drawings and data
Establish project reporting methods
Introduce key integrator and client personnel with overall project respon­sib­ilities
Develop a prelim­inary outline for format of final report
Establish delive­rables
(Also, weekly project meetings attended by all system integrator personnel on project and monthly status review meetings.)

Phase 3: Field Survey

Integrator project team reviews current system, including:
Physical layout
Screen and report requir­ements
Man machine interface
Sequence of operation
Current process overview

Phase 4: Functional Descri­ption

(States functional requir­ements for project.)
Reference request for proposal Involves customer input
Upon final client approval is basis for design document
I/O list
1. Machine identifier
2. Rack identifier
3. Input card identifier
4. Signal type
5. Terminal numbers
6. Signal identifier

Phase 5: Detailed Descri­ption

(Provides implem­ent­ation method for each requir­ement in the functional descri­ption.)
Controls, regulates and directs progress of system develo­pment
Measures technical confor­mance
Maintains project schedule
Delineates internal structure of system (i.e., data dictio­naries, flow charts, logic pseudo code)
Client reviews design progress on regular basis and must approve final document before project can proceed

Phase 6: Acceptance Test Plan & Procedure

(Developed after approval of Phase 4, Functional Descri­ption. This document explains how to test hardware and software to demons­trate confor­mance to system specif­ica­tions. A detailed list of actions and expected results that satisfy all requir­eme­nts.)
Test No. 1: Factory Acceptance Test (at S.I... facility)
    Complete system staging
    Compre­hensive test to demons­trate all hardware and software for the project
Test No. 2: Field Acceptance Test (after system instal­lation)

Phase 7: System Develo­pment

Software Design
Write software specif­ica­tions per the Functional Descri­ption. Specif­ica­tions will consist of data flow diagrams, block schematics (for PLC progra­mming), data dictionary and mini-space (an English language descri­ption of the software functi­ons). The specif­ica­tions will provide enough inform­ation for a software engineer to write progra­mming specif­ica­tions.
Software specif­ica­tions must be reviewed and approved by client before coding is started. Any changes after client review will be regarded as major additions to the contract.
Progra­mming specif­ica­tions will be pseudo code version of the final program, specific to operating system, language and hardware. Review of progra­mming specif­ica­tions will be made prior to final code and implem­ent­ation.
Graphics config­ura­tion: Applic­ation of control and feedback features to the screens as defined in the Functional Descri­ption.
Coding of controls according to the software and program specif­ica­tions

Hardware Design
Verifi­cation of existing customer drawings against actual field condit­ions. Develop demolition drawings to show sequence and conditions applicable to the removal of existing equipment.
Develop system schematics showing terminal numbering, equipment type, etc.
Develop diagrams to show wiring instal­lation, terminal connec­tions, conduit routing and cable type, etc. These will normally be done according to customer's standard cable schedule format.
Develop diagrams for the necessary enclosures and panels for equipment mounting. Drawings will be suitable for bidding and constr­uction by a third party supplier.
Spec­ifi­cations to inform the vendor of the requir­eme­nts necessary in the manufa­cture of the panels, i.e. type of enclosure (NEMA 4, etc.), weld instru­ctions, finish, materials, etc.
Release panel drawings for bid, or according to the procedure for the project (preferred vendor, etc.), and manufa­cture.
Designate delivery time of panels and enclosures

Phase 8: System Integr­ation Task

After completion of software develo­pment and hardwa­re/­sof­tware interf­aces, system hardware and software are integr­ated.
During integr­ation, power is applied to all hardware and burn-in program operates for 100 hours. Purchased hardware and all system periph­erals are inspected and tested to verify that all software and hardware function according to manufa­ctu­rers' specif­ica­tions.
Hardware and software are functi­onally tested and software is modified, as necessary, to assure software modules and hardware elements function as one system

Phase 9: Factory Acceptance Test

Performed at system integrator test facility.
Complete system staged and compre­hensive mock-up test performed to demons­trate all hardware and software.
Daily review of scheduled tests and test results. If necessary, integrator engineers correct any errors discovered and perform regression tests to show correct system perfor­mance.
Client and integrator jointly develop a "­pun­ch" list of items, if any, which require further action and/or correction before shipment.

Phase 10: Support Services

Client must approve Factory Acceptance
Test before shipment
All equipment packed in manufa­ctu­rers' packing boxes
All items in shipment marked separately with shipping labels and clearly marked with special handling instru­ctions Industry standard shipping materials and methods utilized to avoid damage to fragile items
Proper shipping papers and packing slips prepared
Physical audit and inventory of all delive­rables performed and data given to client before delivery
Physical audit and inventory data repeated by integrator after shipment Shipment sent using commercial carriers approved in advance
Close contact maintained with carrier to verify that shipment is received promptly and in good condition

Inst­all­ation Superv­ision
Integr­ator's field instal­lation engine­er(s) will supervise all instal­lation by others and will have the following respon­sib­ili­ties:
Docume­ntation package interp­ret­ation, distri­bution and mainte­nance
System testing prior to commis­sioning
Assist in system training sessions
Work closely with client to respect the schedules and other demands on client personnel during instal­lation

One integrator engineer will be designated to schedule and coordinate all start-up activities with client
Engineer will work closely with client to respect schedules and other demands on client personnel during start-up
Same engineers who were respon­sible for designing the system will be respon­sible for the system start-up

Field Acceptance Test
Training - Management Training Program
Lecture seminar for executives and managers
Present general features and functi­ons** of the system
Techniques for effective management monitoring and control of the system
Discuss possible future develo­pment of the system
Answer partic­ipant questi­ons**
Computer Training Program
For system managers & engineers
Theory of system operation
Hardware config­ura­tio­n/s­ystem components
Software concepts and structure
System interface and data commun­ica­tions
System preven­tative mainte­nance
Operator Training Program
Combin­ation lectur­e/s­eminars and hands-on training for dispat­chers and superv­isors
Focused on individual job assign­ments
Main­tenance Training Program
Combin­ation lectur­e/s­eminars and hands-on training for superv­isory and mainte­nance personnel
Instru­ctions on how to maintain, troubl­e-shoot and adjust system equipment

Phase 11: Docume­ntation

Complete set of manuals of all hardware and standard software products incorp­orated in the system.
Oper­ational docume­ntation for normal use of the system.
Start-up and mainte­nance docume­nta­tion for recovery operat­ions.
Design docume­nta­tion specifying overall system structure.