Process Automation in a Medium-Sized Mechanical Engineering Company. Development of a Systematic Approach for the Identification of Potentials

Table of Contents

1. Introduction

1.1 Problem Definition

1.2 Literature Review

1.2.1 Existing concepts.

1.2.2 Process.

1.2.3 Automation.

1.2.4 Small and medium-sized enterprises.

1.3 Research Question

1.4 Hypotheses

2. Method

2.1 Object

2.2 Procedure and methods

2.2.1 Process analysis.

2.2.1.1 Process identification.

2.2.1.2 Process recording.

2.2.1.3 Process documentation.

2.2.1.4 Process evaluation.

2.2.2 Target Concept Creation

2.2.2.1 Conception of target processes

2.2.2.2 Comparison to the current situation

3. Results

3.1 Process analysis

3.1.1 Process identification.

3.1.2 Process recording.

3.1.3 Process documentation.

3.1.4 Process evaluation.

3.1.5 Summary of the process analysis

3.2 Target Concept Creation

3.2.1 Conception of target process.

3.2.2 Comparison to the current situation

4. Discussion

4.1 Confirmation / Disconfirmation Hypotheses

4.1.1 I. Hypothesis.

4.1.2 II. Hypothesis.

4.1.3 III. Hypothesis.

4.2 Limitation

4.3 Implication

4.4 Conclusion

Objectives and Research Themes

The primary objective of this thesis is to develop a structured, transferable concept for identifying automation potentials within existing processes of small and medium-sized enterprises (SMEs). Faced with increasing competitive pressure and structural deficits in digitisation, many SMEs struggle with the transition to Industry 4.0. This research aims to answer the central question: What does a structured approach to identifying optimization potential as a basis for process automation look like, and what must be considered during its application?

• Analysis of existing process optimization concepts in the literature.
• Development of a structured, three-stage procedure for process analysis and target concept creation.
• Empirical testing of the developed concept through a case study on machine labelling at F Maschinenbau GmbH.
• Evaluation of process efficiency and risk using methods such as Activity Focus Analysis (AFA) and Failure Mode and Effect Analysis (FMEA).
• Derivation of specific recommendations for process automation to reduce errors and costs.

Excerpt from the Book

Summary of Chapters

1. Introduction: Outlines the challenges SMEs face regarding competitiveness and digitisation, establishes the research questions, and formulates the underlying hypotheses.

2. Method: Describes the object of the case study (F Maschinenbau GmbH) and details the developed three-stage conceptual framework for process analysis, evaluation, and target concept creation.

3. Results: Presents the application of the developed concept to the machine labelling process, including detailed findings from process recording, AFA, FMEA, and the definition of a target process.

4. Discussion: Evaluates the validity of the initial hypotheses, discusses the limitations of the case study approach, and highlights the practical implications for the company.

Keywords

SME, Industry 4.0, Process Automation, Process Analysis, Activity Focus Analysis, AFA, Failure Mode and Effect Analysis, FMEA, Digitisation, Value Stream Mapping, Optimization Potential, Machine Labelling, Business Process, Efficiency, Production Management.

Frequently Asked Questions

What is the core focus of this research?

The research focuses on creating a systematic, structured approach for small and medium-sized enterprises to identify and implement automation potentials within their existing business processes.

What are the primary themes covered in this thesis?

The core themes include the specific structural challenges of SMEs, process modelling, Industry 4.0 applications, quality management tools (AFA and FMEA), and the transition from manual to automated workflows.

What is the central research question?

The central question is how a structured procedure for identifying optimization potential as a basis for process automation should be designed and applied in a medium-sized enterprise.

Which scientific methods are utilized?

The study employs a multi-method approach, including literature review for concept comparison, expert interviews for process recording, Activity Focus Analysis (AFA) for process evaluation, and Process FMEA for risk assessment.

What topics are discussed in the main body?

The main body covers the detailed identification and documentation of the machine labelling process at F Maschinenbau GmbH, followed by an in-depth evaluation and the proposal of a comprehensive target concept.

Which keywords best describe this study?

Key terms include SME, Process Automation, AFA, FMEA, Digitisation, and Process Optimization.

Why is the machine labelling process used as a case study?

This process was selected due to its high manual effort and significant error rate, making it an ideal candidate to demonstrate the practical effectiveness of the proposed automation concept.

How does the proposed concept minimize operational risks?

By using the Process FMEA, the research identifies critical failure modes in the current process and integrates remedial measures directly into the target process design to ensure reliability.

What is the expected benefit of this research for the client company?

The client expects a reduction in manual data input, improved process reliability through automation, and lower costs by eliminating redundant and non-value-adding process steps.