Installation of Automation

“Back in the Day ” if you wanted to obtain employment in the field of Installing Automation equipment you would probably have needed to have served a 4 year apprenticeship in mechanical fitting. That is probably still true today but companies training mechanical fitters are less and less, but all is not lost,  in todays modern world it is possible to either go to college and maybe take a NVQ diploma and if you show a technical attitude you may be lucky to get a job assembling equipment in a workshop then biding your time to go on the road with that company. Assuming you can get employment and then want to go out on sites you will probably need other certificates to cement your position. To be a mechanical installer you will need to show a hands-on dexterity, basic mathematical skills and an ability to read drawings and manuals. It is important to have a personality that can get on well in a team situation or also to have the confidence to work independently.

In my experience one of the fundamental skills that is required of a Mechanical Technician or Fitter is the ability to read Engineering drawings, whether it be an overall layout of the factory where the Installation is taking place, a detailed breakdown of the machinery dimensions or a Technical Manual of the full machine. Asking a mechanical technician to install automation without being able to read engineering drawings is like asking a chef to bake a complex souffle while blindfolded—you might get something edible, but it’s probably going to collapse. In the world of robotics and automation, precision isn’t just a goal; it’s the baseline. Here is why that skill is non-negotiable:

1. Precision and Tolerances

Automation relies on repeatable, exact movements. Engineering drawings specify GD&T (Geometric Dimensioning and Tolerancing), which tells the technician exactly how much “wiggle room” exists. If a robotic arm base is off by even a fraction of a millimeter because a technician misread a datum feature, the entire production line could fail down the road.

2. Assembly Sequencing

Robotic cells are packed with sensors, pneumatic lines, and complex bracketry. Drawings (especially Exploded View drawings) provide the “map” for the build. Without them, a technician might install a component in a way that blocks access to a critical sensor or prevents a safety gate from closing properly.

3. Safety and Structural Integrity

Automation involves high speeds and heavy forces. Engineering drawings specify:

• Fastener torque specs: Ensuring bolts don’t shear or loosen under vibration.

• Load-bearing points: Ensuring the robot is anchored to the floor or gantry correctly.

• Clearance zones: Marking “no-go” areas where the robot’s reach could cause a collision.

4. Communication and Troubleshooting

The drawing is the “source of truth” between the engineer who designed the system and the technician building it. If a part doesn’t fit, the technician needs to read the drawing to determine if the part was manufactured incorrectly or if they are simply installing it backward.

The Technician’s    “Mental Toolkit”

So as well as having the correct tools for the job, the Installation Technician has to acquire a fair amount of knowledge to make himself a valuable asset to a company. Beyond just “looking at the picture,” a top-tier technician needs to understand:

Orthographic Projections: Visualizing a 3D object from 2D top, front, and side views.

BOM (Bill of Materials): Identifying exactly which screw, motor, or plate goes where. Usually if one is on a new installation is best to check that all the parts that are supposed to be there have arrived. May sound like a crazy thing but I have known it to happen where parts have not been sent and panic sets in and Taxis are ordered to bring parts, obviously the qicker this can be relayed back to the Main Office the more chance the situation can be retrieved. Also watch out for danaged or broken parts (does happen in Transit).

Schematics: Understanding how the pneumatic or hydraulic lines integrate with the mechanical frame. A valuable knowledge I have found is to know the standard pneumatic symbols for when you are piping up machines and pneumatic cabinets.

While a Technician might be able to “bolt things together,” a professional who understands drawings ensures the system is safe, functional, and durable. It’s the difference between a “mechanical assembly” and a “precision instrument.”

Assuming your employer is happy with your hands-on experience then you will need some other paperwork to get onto a customers site. A CSCS card is the usual minimal requirement for factory automation work whilst the CCSNG safety passport is required for Construction & some Engineering work sites. If you are contemplating pursuing a career down the contracting path it is advisable to have both thus covering all options. What are the rules and costs of these cards ?

The CSCS card is issued by the (Construction Skills Certification Scheme) in the UK and more details can be found at http://www.cscs.uk.com    The card lasts for 5 years before you need to renew, it costs £36 plus a mandatory Health & Safety Test of £22.50  so total cost is £58.50 (it is free for an apprentice during the training period). The test is a multiple choice done on screen at one of the local test places that can be found on their website.

The CCNSG safety passport is a 2 day course costing £155 and lasts for 3 years before renewal, details can be found at  http://www.ecitb.org.uk  it is issued by the Engineering & Construction Industry Training Board and is mainly a Health & Safety Certificate and is a prerequisite for site entry on Construction sites. So both these schemes deal mainly with the Health & Safety aspect but in the case of the CSCS card depending on the level or skill that you are trying to attain you will have to provide some evidence that you hold the qualifications. A further layer of security is sometimes asked for by customer sites, Companies are using a third party verification company to check out the details of your qualifications/past work history and some want background disclosure checks from Government agencies.

So we can get on site, then what ? well you will be designated a “Person of Contact” (usually the Project Engineer or Manager) then each day you will have to sign on the Permit before starting any work, this is usually compulsory depending on the customers site, then you will be allowed on to where the actual work is taking place. Obviously it is your Person of Contact who issued the permit to make sure the area has finished any production in that area or be aware of any hazards that are around. When getting to your place of work if it is previously been a “live” site then LOTO safety procedures must be used (That will be covered in a further posting).When all is safe to go, make sure you wear all the required PPE, sites do vary as to what is mandatory, make sure you stick to all the safety procedures, nowadays people come around checking and watching then reporting back to the Safety Officer, some companies have a policy for studying cameras that are in the location, so there should be no short cuts on safe working procedures. At the end of a safe and hopefully fruitful day, LOTO might need to be reversed to let equipment go live again, or maybe its a new installation and nothing live yet, Permits will need to be signed off with the Person of Contact.

Is there anything else required, well from a work experience it may be worth having the following

IPAF Licence,  PAL card (Powered Access Licence) – for operators of a mobile elevating work platform. This is valid for 5 years and requires the operator to take a day course and pass the test at the end.. The courses  take place at local accredited centres and costs are around £350 per operator but can depend on how many categories you wish to operate. 

Incorporate a Safety Harness Practical Training course in with the IPAF   plus see  Our ( WORKING AT HEIGHTS POST )

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