ten strategies

 The USA Principle

The USA Principle is a commonsense approach to automation and process improvement

projects. Similar procedures have been suggested in the manufacturing and automation trade literature, but none has a more captivating title than this one. USA stands for

(1) understand the existing process, (2) simplify the process, and (3) automate the process. A statement of the USA Principle appeared in an article published by the American

Production and Inventory Control Society [5]. The article is concerned with implementing enterprise resource planning (ERP, Section 25.7), but the USA approach is so general

that it is applicable to nearly any automation project. Going through each step of the

procedure for an automation project may in fact reveal that simplifying the process is sufficient and automation is not necessary.

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There are additional approaches not discussed here, but in which the reader may be interested—for

example, the ten steps to integrated manufacturing production systems discussed in J. Black’s book The Design

of the Factory with a Future [1]. Much of Black’s book deals with lean production and the Toyota Production

System, which is covered in Chapter 26 of the present book

Understand the Existing Process. The first step in the USA approach is to comprehend the current process in all of its details. What are the inputs? What are the outputs? What exactly happens to the work unit2

between input and output? What is the

function of the process? How does it add value to the product? What are the upstream

and downstream operations in the production sequence, and can they be combined with

the process under consideration?

Some of the traditional industrial engineering charting tools used in methods analysis are useful in this regard, such as the operation chart and the flow process chart [3].

Application of these tools to the existing process provides a model of the process that can be

analyzed and searched for weaknesses (and strengths). The number of steps in the process,

the number and placement of inspections, the number of moves and delays experienced by

the work unit, and the time spent in storage can be ascertained by these charting techniques.

Mathematical models of the process may also be useful to indicate relationships between input parameters and output variables. What are the important output variables?

How are these output variables affected by inputs to the process, such as raw material

properties, process settings, operating parameters, and environmental conditions? This

information may be valuable in identifying what output variables need to be measured

for feedback purposes and in formulating algorithms for automatic process control.

Simplify the Process. Once the existing process is understood, then the search

begins for ways to simplify. This often involves a checklist of questions about the existing

process. What is the purpose of this step or this transport? Is the step necessary? Can it

be eliminated? Does it use the most appropriate technology? How can it be simplified?

Are there unnecessary steps in the process that might be eliminated without detracting

from function?

Some of the ten strategies for automation and process improvement (Section 1.4.2)

can help simplify the process. Can steps be combined? Can steps be performed simultaneously? Can steps be integrated into a manually operated production line?

Automate the Process. Once the process has been reduced to its simplest form,

then automation can be considered. The possible forms of automation include those

listed in the ten strategies discussed in the following section. An automation migration

strategy (such as the one in Section 1.4.3) might be implemented for a new product that

has not yet proven itself.

1.4.2 Ten Strategies for Automation and Process Improvement

Applying the USA Principle is a good approach in any automation project. As suggested

previously, it may turn out that automation of the process is unnecessary or cannot be

cost justified after the process has been simplified.

If automation seems a feasible solution to improving productivity, quality, or other

measure of performance, then the following ten strategies provide a road map to search

for these improvements. These ten strategies were originally published in the authour They seem as relevant and appropriate today as they did in 1980.