A manufacturing company gets an important contract. Its monthly production needs increase, but the factory hasn’t suddenly gained more area for floor, skilled employees or hours of work per daytime. Although adding another shift may temporarily improve the situation, it may also create new jobs in the form of supervision, training, or the need for quality control.
Image credit: automatedsolutions.com.au
These situations reveal a very important motive for the use of robotic automation. Robotics goes beyond replacing people with machines. The right application can transform how manufacturers use their production capacity.
Take a look at the seconds that disappear between products
Inefficiency in manufacturing doesn’t need to be dramatic. Suppose an operator spends 15 seconds arranging the component after which another 10 seconds are spent applying the material, and a few minutes transferring it onto the next task. The time difference could seem minor for a single part. Repeated thousands of times however, those seconds become substantial production time.
The same applies to wasted material. A tiny amount of leftover coating or dispensing material multiplied in a production run with a high volume can result in an expense that is significant.
The companies that are considering robotic automation Australia will benefit from studying these small loss, repeated ones before they choose the equipment they will purchase. The analysis conducted by ASA’s Needs Analysis is designed to identify bottlenecks, problems with quality, waste and other constraints to the process which could affect the automation project.
A Robot must be able to integrate the Process Itself
A robot is just one of many engineering choices. The system may also need guarding, tooling and controls, sensors fixtures, conveyors, electrical integration, as well as communication with the existing production equipment. Engineers need to consider the robot’s reach and payload, as well as how it interact with its surroundings and move around.
The ASA approach to FANUC robot automation encompasses the development of concepts and systems including CAD Simulation, offline programming. Digital simulation lets engineers investigate configurations and estimate cycles before the system is operational at the customer’s factory floor. This is especially useful when space is constrained or if new robotics are required to integrate with an established production line.
Painting and dispensing show why the importance of repeatability is evident.
Certain manufacturing processes show the importance of controlled motion particularly well. Imagine applying a coating to hundreds of parts. It’s not enough just to finish every component in a short time. The movement, distance, speed, and application need to be monitored from the beginning of the production line until the final.
The experts at ASA are proficient in painting and dispensing across industries such as automotive and aerospace. In these environments, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially hazardous processes.
An improved control over materials that are discarded can help improve productivity by cutting down on the amount of waste material consumed.
The System Needs People Even After Installation
Automation doesn’t eliminate the need for manufacturing expertise. It transforms the knowledge needed to run and maintain the manufacturing process.
Employees must be instructed to operate equipment with care and to recognize abnormal behavior, troubleshoot faulty components, and take care of any maintenance that is required. Production requirements can change as time passes, which means that the processes and programs need to be adapted.
ASA provides training on-site for safe operation, programming, troubleshooting, and mechanical and electrical maintenance. The company provides continuous maintenance and services to ensure that the equipment is in good repair and wear and tear issues are taken care of.
Capacity means more than just working faster
An increase in capacity for Australian manufacturers doesn’t necessarily mean buying a bigger building or adding more employees on repetitive processes. It is sometimes better to ask if the production process could be redesigned.
ASA has been developing and integration of automation systems since 2002. It has assisted manufacturers in Australia and also projects across the globe. The approach is a combination of needs analysis as well as engineering simulation. FANUC integration as well as training and maintenance.
Automation is not the goal. A worthwhile system should give manufacturers something tangible in the form of more reliable production that is consistent in quality, more secure processes, less waste, or a larger capacity for the factory that it currently operates.