Wauseon Machine's Automation Project Process: Turning Complex Challenges into Seamless Solutions

For 40 years, Wauseon Machine has been transforming visions into reality, one meticulously crafted automation solution at a time. More than just a machine shop, they're a single-source powerhouse for automation solutions, tube forming technologies, precision machining, and fabrication. As part of their expertise in automation, they’ve developed a proven methodology known as the Automation Project Process (APP). This process is the cornerstone of their approach, ensuring reliable, consistent results by turning complex challenges into seamless, customer-centric automation solutions, backed by engineering expertise and cutting-edge technology.

What is APP?

According to Kyle Mahan, Vice President and General Manager at Wauseon Machine, the Automation Project Process is a carefully designed, phase-gate process that guides custom automation projects through distinct stages, from the initial project award to final deployment on the customer's floor.

At Wauseon Machine, the APP serves as the structured process for managing projects. The primary objective is to ensure consistent, high-quality results for our customers. This is achieved through the process's multiple steps, which allow for the measurement of success at each stage.

The Five Key Phases of the APP

Wauseon Machine’s phase-gate process consists of five key phases:

• Quote and Order Acceptance: This initial phase involves the sales and applications teams, focusing on scoping the project and thoroughly understanding the customer's needs.
• Concepting: The engineering and project management teams collaborate to solidify the project concept.
• Development: The engineering team takes the lead, developing a complete design that meets and is approved by the customer.
• Build: The equipment is built and debugged, ensuring it meets all agreed-upon requirements.
• Customer Acceptance: The equipment is run on the customer's floor, verifying that it performs as initially defined in phase one, leading to successful project closure.

Key Performance Indicators (KPIs)

Wauseon Machine utilizes Key Performance Indicators (KPIs) to measure project success and performance. A crucial metric is "first-time yield," also known as "first pass." The goal is to ensure that when a customer arrives to run the equipment for the first time, it operates seamlessly. The APP is instrumental in achieving these predictable outcomes, scaling from small to large projects with consistent reliability.

The aim is to guarantee that from project award to deployment, the equipment performs flawlessly upon the customer's initial run.

The APP also fosters a culture of continuous improvement. By analyzing and learning from any challenges encountered, Wauseon Machine incorporates those lessons into future projects, further refining its processes.

Customer Involvement: A Collaborative Approach

Wauseon Machine emphasizes customer involvement throughout the entire APP process, from the initial concept to final deployment. Project managers, all PMP certified, manage each phase gate, ensuring that all standards are met and signed off by the customer.

In addition to phase-gate approvals, Wauseon Machine maintains open communication through weekly meetings and summary emails. These updates keep customers informed of the project's progress, schedule adherence, and any challenges or needs that require their attention. This collaborative approach ensures that the project remains a two-way street, with both Wauseon Machine and the customer working together to achieve success.

What Sets Wauseon Machine Apart?

Wauseon Machine’s project management approach has been developed and refined over many years. With a strong emphasis placed on this process, issues and challenges are proactively addressed, leading to consistent results. Wauseon Machine boasts a KPI of over 90% for on-time equipment run-off, significantly higher than the sub-80% range of most competitors.

"By putting such an emphasis on this process, we're able to head off issues and challenges before they arise, and when they do arise, we're able to handle them in a much faster manner," says Kyle Mahan. "Our KPI currently sits at 90%, which is extremely high for custom automation."

Wauseon Machine's dedication to project management excellence ensures customer satisfaction and the delivery of successful automation solutions.

For more information about Wauseon Machine and its Automation Project Process, please visit https://wauseonmachine.com/.