Field Services

Futura Automation offers our clientele design, machinery and system programming, manufacturing consulting and equipiment commissioning services at a competitive rate based on the expertise of our field service partners.

Transport, Meals and Accommodations:

Accommodations are $150 per night
Transportation is billed at Cost (flights and rental cars)
Meals are billed at $100 per day
Travel time is billed at 1/2 the rate of time on customer premises

SERVICES

Robot System Design, Programming, Commissioning – $200.00 / hour

ABB, Denso, Fanuc, Kawasaki, Kuka, Omron-Adept, Universal, Yaskawa/Motoman
Applications Served: Assembly, Dispensing, Fastening, Finishing, Handling, Machine Tending, Palletizing
Conceptualize and design robotic controls including writing programs from scratch and integrating with other components such as Flexfactory feeders, PLC (Rockwell, Siemens, Omron, etc), motion systems (Beckhoff, B&R, Trio Systems, Galil, etc), vision systems (Cognex, Keyence, etc), VFD and Servo drive integration
Perform safety risk analysis and safety circuit integration
Apply “Visual Components” software to develop automation designs and 3D visual simulations
Perform payload checks, reach studies, and determine I/O requirements. Integrate, sets up, and configure vision systems

MES, IIOT and SCADA System Development (Tulip, Ignition, Wonderware, Labview, others) – $150.00 / hour

Plant floor data collection / IIOT; remote and wireless networking and communications
Digital Visual Work Instructions, Digital Visual Training, Inventory Management, Asset Management
Lab Automation, Quality Audit and Tracking, – Measure first pass yield and quality defects by product variety to improve product design; ISO 9000 documentation / Six Sigma processes
Machine Maintenance and Monitoring – Third-party (PLC / CNC) system data: Bring in and visualize data from other systems and data sources. Build dashboards for all of factory data in one easy-to-understand view.
OEE, Production Monitoring, LEAN Manufacturing – Track step, process and cycle time by product and worker to optimize production.

Full Stack Computer Programming Services – $150.00 / hour

Front-end web development: JavaScript, CSS, HTML
Back-end web development: JavaScript, Java, Python, PHP, Ruby
Mobile and Remote development: Swift, Java, C#, OPC-UA, MQTT
Desktop applications: Java, C++, Python
Systems programming: C, Rust, LINUX

-----Factory Floor Audit to Identify Productivity Opportunities - $150.00 / hour

Gemba Walk: Help a production team do the job right the first time and prevent production errors from happening
Increase operator productivity by comprehensively guiding them through complex processes
Reduce human error through easy to follow, interactive instructions that guide your team as they perform their daily tasks
Augment operator engagement through interactive work instructions
Minimize quality defects through automatic in-line quality inspections
Gain visibility into operator performance through real-time data and bench-marking
Increase productivity by tracking the most relevant key performance indicators (KPIs) of operations
Easily visualize costs generated by production errors, rework and scrap.Reduce the cost of poor quality by minimizing rework, scrap and defective products
Initial 2 hour team meeting to discuss and identify cost-saving opportunities
Further 30 to 60 minute one on one sessions with stakeholders to further review opportunities, document and report

-----Machine Risk Assessment and Safety Audit - $150.00 / hour

Detailed machine evaluations to OSHA 1910 standards
Stop Time Testing
Recommendations for the proper point-of-operation safeguarding methods or devices
Evaluation of electrical and related documentation for compliance to “control reliability” standards.
Recommendations for additional Part fixtures and hand tools to eliminate “hands-in-die” operations
Forklift safety recommendations and machine collision detection upgrades
Recommendations for Automation upgrades to maximize safety productivity
Build and Deploy mechanical machine guarding systems, OSHA and ISO compliant safety controllers, safety light curtains, safety door interlocks, safety laser scanners, safety floor mats
Long and short-term safety strategies to increase productivity while maintaining a high level of operator safety.
Cost = Average time for audit = one hour per machine + required hardware and labor to implement recommendations

-----Plant Equipment Networking to ERP System Integration (IIOT) - $200.00 / hour

Paint a detailed view of your work processes with real-time data from your people and machines.
Provide department, division or plant-wide display of OEE and other KPIs
Partner example 1: https://www.advantech.com/industrial-automation/industry4.0/
Partner example 2: https://www.klipfolio.com/resources/kpi-examples
Work with IT professionals to ensure seamless and secure network interface
Cost = Hourly depending on extent of project + required hardware and labor to implement recommendations

-----Quality Control Integration: Metrology, Gaging and Machine Vision - $150.00 / hour

Connect measurement and inspection tools to the lean apps built to increase production visibility and perform faster root cause analysis
Design 2D and 3D machine vision algorithms using standard or custom tools
Acquire and deploy machine vision components: conveyor, lighting, position stages, work-holding, , lenses and filters, cameras, computers
Implement machine vision systems and automated gaging systems, as required
Cost = Hourly depending on extent of project plus equipment

-----Machine Maintenance, Repair, Monitoring Sensor Selection and Integration - $150.00 / hour

Connect position encoders, speed monitors, pressure and force sensors, temperature, flow, level, load, weight, vibration and humidity sensors to detect and solve issues faster.
Wired or wireless networking of machine sensors, depending on cost-benefit analysis
Upgrade, rebuild or repair existing machine and robot controls, motors, gearing, valves
Partner example: https://buy.advantech.com/Search.aspx?skey=mesh

-----Predictive Maintenance Algorithm Design and Integration - $200.00 / hour

Reduce unplanned downtime with optimized maintenance scheduling and failure prevention.
Boost Overall Equipment Effectiveness (OEE) by optimizing the production conditions of each machine and process.
Maximize throughput by identifying process bottlenecks, and testing alternative setups without affecting production.
Reduce defects and improve product quality with accurate predictive quality and optimized machine performance.
Reduce time-to-repair and cost-to-repair through accurate issue categorization and alerts.
Reduce unplanned downtime with optimized maintenance scheduling and failure prevention.
Build new revenue streams by providing digital services to customers such as PdM dashboards, optimized maintenance schedules, or a technician dispatch service.
Improve customer satisfaction by sending customers automated alerts when parts need to be replaced or serviced, strengthening your brand, and keeping a competitive advantage.
Screen example: https://www.seebo.com/predictive-maintenance/

-----Automated Machine and Robotics Cell Design and Integration - $200.00 / hour

Design data collection systems using existing or new controls and sensors
Process / machine concept development
ROI and benefit analysis of new machines or processes
Machine Scope of Work and BOM development
Machine fabrication, Factory Acceptance Testing, installation and startup

-----Controls and Sensors Installation, Low Voltage Electrical Wiring - $130.00 / hour

Identify required sensors
Qualified installation of all low voltage (less than 120vac) devices) including mounting, programming, testing
Acquire and Deploy ANDON systems
Acquire and Deploy production and quality plant display dashboards

-----Futura Automation Workstation Design: Screen and Report Configuration - $200.00 / hour

Track step, process and cycle time by product and worker to optimize production.
Monitor process completions in real-time to detect and solve bottlenecks faster
Measure first pass yield and quality defects by product variety to improve product design
Third-party (PLC / CNC) system data: Bring in and visualize data from other systems and data sources. Build dashboards for all of factory data in one easy-to-understand view.
Error-proof your operations and guide production teams as they perform their tasks by Poka Yoke techniques and digital work instructions to guide assembly
Cost based per screen developed

-----Production Staff Training - $150.00 / hour

Detailed operator and management training on all solutions provided: how to maintain tools
Kaizen : Provide your team with feasible targets and objective data-driven feedback. Instantly see the impact of your coaching on your operations in real-time.
Sensor, programmable controller, robot and drive setup and maintenance training
Tulip software screen development training for digital work instructions and detailed quality and production reports; Overall Equipment Efficiency (OEE) measurement
Reduce new employee on-boarding costs by not having to allocate a full-time training buddy and speeding up the training process.
Decrease the time and effort required to on-board new employees through self-guided training modules and digital work instructions
Minimize turnover costs through a more efficient training process that speeds up the on-boarding of new hires
Raise new hire engagement through ‘gamified’ training programs

Transport, Meals and Accommodations:

Accommodations are $150 per night

Transportation is billed at Cost (flights and rental cars)

Meals are billed at $100 per day

Travel time is billed at 1/2 the rate of time on customer premises

SERVICES

ABB, Denso, Fanuc, Kawasaki, Kuka, Omron-Adept, Universal, Yaskawa/Motoman

Applications Served: Assembly, Dispensing, Fastening, Finishing, Handling, Machine Tending, Palletizing

Perform safety risk analysis and safety circuit integration

Apply “Visual Components” software to develop automation designs and 3D visual simulations

Perform payload checks, reach studies, and determine I/O requirements. Integrate, sets up, and configure vision systems

Plant floor data collection / IIOT; remote and wireless networking and communications

Digital Visual Work Instructions, Digital Visual Training, Inventory Management, Asset Management

Lab Automation, Quality Audit and Tracking, – Measure first pass yield and quality defects by product variety to improve product design; ISO 9000 documentation / Six Sigma processes

Machine Maintenance and Monitoring – Third-party (PLC / CNC) system data: Bring in and visualize data from other systems and data sources. Build dashboards for all of factory data in one easy-to-understand view.

OEE, Production Monitoring, LEAN Manufacturing – Track step, process and cycle time by product and worker to optimize production.

Front-end web development: JavaScript, CSS, HTML

Back-end web development: JavaScript, Java, Python, PHP, Ruby

Mobile and Remote development: Swift, Java, C#, OPC-UA, MQTT

Desktop applications: Java, C++, Python

Systems programming: C, Rust, LINUX

Gemba Walk: Help a production team do the job right the first time and prevent production errors from happening

Increase operator productivity by comprehensively guiding them through complex processes

Reduce human error through easy to follow, interactive instructions that guide your team as they perform their daily tasks

Augment operator engagement through interactive work instructions

Minimize quality defects through automatic in-line quality inspections

Gain visibility into operator performance through real-time data and bench-marking

Increase productivity by tracking the most relevant key performance indicators (KPIs) of operations

Easily visualize costs generated by production errors, rework and scrap.Reduce the cost of poor quality by minimizing rework, scrap and defective products

Initial 2 hour team meeting to discuss and identify cost-saving opportunities

Further 30 to 60 minute one on one sessions with stakeholders to further review opportunities, document and report

Detailed machine evaluations to OSHA 1910 standards

Stop Time Testing

Recommendations for the proper point-of-operation safeguarding methods or devices

Evaluation of electrical and related documentation for compliance to “control reliability” standards.

Recommendations for additional Part fixtures and hand tools to eliminate “hands-in-die” operations

Forklift safety recommendations and machine collision detection upgrades

Recommendations for Automation upgrades to maximize safety productivity

Build and Deploy mechanical machine guarding systems, OSHA and ISO compliant safety controllers, safety light curtains, safety door interlocks, safety laser scanners, safety floor mats

Long and short-term safety strategies to increase productivity while maintaining a high level of operator safety.

Cost = Average time for audit = one hour per machine + required hardware and labor to implement recommendations

Paint a detailed view of your work processes with real-time data from your people and machines.

Provide department, division or plant-wide display of OEE and other KPIs

Partner example 1: https://www.advantech.com/industrial-automation/industry4.0/

Partner example 2: https://www.klipfolio.com/resources/kpi-examples

Work with IT professionals to ensure seamless and secure network interface

Cost = Hourly depending on extent of project + required hardware and labor to implement recommendations

Connect measurement and inspection tools to the lean apps built to increase production visibility and perform faster root cause analysis

Design 2D and 3D machine vision algorithms using standard or custom tools

Acquire and deploy machine vision components: conveyor, lighting, position stages, work-holding, , lenses and filters, cameras, computers

Implement machine vision systems and automated gaging systems, as required

Cost = Hourly depending on extent of project plus equipment

Connect position encoders, speed monitors, pressure and force sensors, temperature, flow, level, load, weight, vibration and humidity sensors to detect and solve issues faster.

Wired or wireless networking of machine sensors, depending on cost-benefit analysis

Upgrade, rebuild or repair existing machine and robot controls, motors, gearing, valves

Partner example: https://buy.advantech.com/Search.aspx?skey=mesh

Reduce unplanned downtime with optimized maintenance scheduling and failure prevention.

Boost Overall Equipment Effectiveness (OEE) by optimizing the production conditions of each machine and process.

Maximize throughput by identifying process bottlenecks, and testing alternative setups without affecting production.

Reduce defects and improve product quality with accurate predictive quality and optimized machine performance.

Reduce time-to-repair and cost-to-repair through accurate issue categorization and alerts.

Reduce unplanned downtime with optimized maintenance scheduling and failure prevention.

Build new revenue streams by providing digital services to customers such as PdM dashboards, optimized maintenance schedules, or a technician dispatch service.

Improve customer satisfaction by sending customers automated alerts when parts need to be replaced or serviced, strengthening your brand, and keeping a competitive advantage.

Screen example: https://www.seebo.com/predictive-maintenance/

Design data collection systems using existing or new controls and sensors

Process / machine concept development

ROI and benefit analysis of new machines or processes

Machine Scope of Work and BOM development

Machine fabrication, Factory Acceptance Testing, installation and startup

Identify required sensors

Qualified installation of all low voltage (less than 120vac) devices) including mounting, programming, testing

Acquire and Deploy ANDON systems

Acquire and Deploy production and quality plant display dashboards

Track step, process and cycle time by product and worker to optimize production.

Monitor process completions in real-time to detect and solve bottlenecks faster

Measure first pass yield and quality defects by product variety to improve product design

Third-party (PLC / CNC) system data: Bring in and visualize data from other systems and data sources. Build dashboards for all of factory data in one easy-to-understand view.

Error-proof your operations and guide production teams as they perform their tasks by Poka Yoke techniques and digital work instructions to guide assembly