Course: Advanced Automation Design

A 12-module course covering the full arc of an automation project — from selecting an integrator to signing contracts, from concept design to sizing math and controls integration. Built for DC engineers, project leads, and operations directors who are buying or delivering a $5M–$100M+ automation system. By the end you’ll be able to evaluate integrators, read and challenge a concept design report, understand the engineering math behind sizing decisions, and negotiate a contract that protects your interests.

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Modules

1. Integrator Project Lifecycle — 8-phase map; 18–36 month timeline; FAT/SAT protocols; milestone billing structure
2. Integrator Project Team — 10 roles with phase loads; 5 handoff failure modes and structural fixes
3. Integrator Landscape — 4 archetypes; 9 full-line integrators with revenue/strengths/weaknesses; selection framework
4. Concept Design Report — 40–100 page structure; ROM ±30–50% budget; DES simulation assumptions; steering committee questions
5. Firm Design Phase — BOD, FDS, ICD completeness checklist; Class 1 ±10% estimate; 80/20 config-customization split
6. Automation Project Contracts — lump sum/GMP/T&M/pay-per-pick; punch list A/B/C; LDs; carve-outs; retainage
7. Throughput Math - Sortation — CPM formula; 80% nameplate rule; surge math; gap requirements; merge efficiency
8. AS-RS Sizing Methods — Bozer & White SC/DC formulas; FEM 9.851; double-deep penalty; AutoStore sizing
9. AMR Fleet Sizing — Little’s Law fleet formula; 70% utilization limit; M/G/1 math; 69-AMR worked example
10. Reliability and Design Safety Factors — 1.25–1.5× rule derivation; series reliability; MTBF/MTTR; P80 buffer sizing
11. PLC-WCS Integration — ISA-95 levels; PLC/WCS boundary; vendor WCS architectures; OT/IT security segmentation
12. WMS Configuration vs Customization — cost multipliers (1.5–3× impl, 2–5× upgrade); Manhattan/BY/SAP treatments; integration methods