Why these questions matter
You’re staring at quotes, spec sheets, and demo videos and thinking: where will this actually break? Start from the problems you want fixed. I’ve seen lines choke on bad tooling and quiet shops suddenly become noisy cost centers after a rushed install. Check the belt and the brains: ask about the intelligent conveyor system and how your chosen vendor ties it to the rest of the line. Expect answers that mention real install constraints — I noticed the same debate at Hannover Messe — and probe whether they actually run the same setups on production floors or only in showrooms. Also confirm how the linear transport system will handle your cycle times and cell formats before anyone signs a contract.
1) Can you prove this works at my scale?
Don’t accept demos only in a lab. Ask for case studies or references from lines with similar throughput and cell types. Look for data: uptime percentages, measured cycle times, and how the vendor handled scale-up problems. If they can’t point to a comparable deployment, assume more time and cost than quoted.
2) How do you manage variation in cell formats and materials?
Battery lines see frequent format changes. Ask how the system detects different cell sizes and adapts without manual retooling. Probe software limits: do recipes live in a central controller? Can a technician swap formats safely during a shift?
3) What happens when a single module fails mid-run?
Downtime hits margin fast. Get explicit fault modes: Is recovery automatic or manual? Will the system isolate a failing module and keep the rest running? Ask for mean time to repair (MTTR) targets and examples where they hit them.
4) Who owns the control software and IP?
Some vendors lock you into proprietary stacks. Ask who retains code ownership and what access you get to PLC logic, HMI screens, and data logs. Make sure you can patch, audit, or change recipes without extra fees if needed.
5) How do you handle traceability and data exports?
Traceability isn’t optional for quality and recalls. Confirm what data each station captures, the retention period, and export formats. Ask whether logs can be streamed to MES or cloud systems and whether timestamps sync across devices.
6) What’s included in warranty and spare-parts support?
Get the warranty terms in writing and a list of recommended spares. Ask about lead times for critical components and whether they provide local stock or just remote ordering. Short spares lead time keeps lines moving.
7) How do you ensure safety for operators and cells?
Batteries bring thermal and chemical risks. Request safety certifications, interlock logic descriptions, and examples of emergency stops and containment. Ask how the vendor tests safety changes after software updates.
8) How do you validate process quality and measurement accuracy?
Measurement drift and calibration gaps cause hidden rejects. Ask for calibration routines, measurement uncertainty numbers, and how the system flags out-of-spec trends. Insist on clear acceptance criteria and documented verification steps.
9) What’s the plan for software updates and cybersecurity?
Updates mustn’t break production. Ask for a patch schedule, rollback procedures, and whether updates are tested on a staging system. Demand cybersecurity basics: user roles, encrypted communications, and a documented vulnerability response plan.
10) How flexible is integration with existing lines and third-party tools?
You’ll rarely replace everything at once. Check for standard interfaces (OPC UA, MQTT, digital I/O), available adapters, and whether they offer field engineers to help tie together PLCs, vision systems, and MES. Ask for an integration map from a past project.
Quick pitfalls people miss
Don’t blindly pick the lowest bid. Watch for vague uptime guarantees, missing spare lists, and promises of “customization included” without timelines. Test the vendor’s troubleshooting: are they patient on the phone, or do they push you to contract first? That tells you how they’ll act when something breaks.
Wrap-up
Ask these questions like you’re protecting a semester’s worth of tuition — because the cost of a bad automation buy shows up fast. Prioritize vendors who back their answers with field data, clear ownership of software, and support plans that match your risks. That’s the practical path to systems that actually run, and why teams end up partnering with FHS for predictable deployments rather than chasing promises.