A manufacturer wins a major contract. While the requirements for monthly production have increased, the facility does not suddenly have more floor space or experienced employees. It is possible to add another shift temporarily, but it can create new labor or training, supervision and quality-control demands.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. It’s not just about replacing people with a machine. It can be used to alter the method by which manufacturers use their existing capacity for production.
Take a look at the time that passes between the products
Manufacturing inefficiency doesn’t have to be evident. Imagine a worker spending 15 seconds searching for a piece of equipment after which they spend 10 seconds putting the material, and then a few seconds to transfer it. For one part the difference appears to be insignificant. It’s a lot when multiplied by thousands.
The same is true for wasted material. A small amount of excess coating or dispensing material multiplied in a production run with a high volume could result in a significant expense.
Before selecting the equipment they need, businesses considering robotic automation Australia can gain from analysing the small loss. ASA’s needs analysis aims to find bottlenecks and quality issues, waste and other process constraints which could impact an automation project.
A Robot must be able to integrate the Process Around It
A robot’s selection is only one decision in engineering. The system will also require guarding, tooling, controls, sensors conveyors, fixtures electronic integration, and connectivity with existing production equipment. Engineers should take into consideration the payload, reach and range as well as how the robot will be able to move and interact within its environment.
ASA’s approach to FANUC robot automation is based on concept development, system design along with CAD Simulation and offline programming. The digital simulation allows engineers analyze configurations, estimate cycles time and allow them to test the system before it becomes operational on the customer’s floor. This is especially helpful when there is a shortage of space or if new robotics require to be incorporated into existing production lines.
Dispensing and painting demonstrate why Replicability is Critical.
Some manufacturing processes illustrate the value of controlled movement especially well. Imagine coating hundreds of components. The end goal isn’t simply finishing each part quickly. It is crucial to manage the speed, distance and movement of each part from the beginning to the very end.
ASA has specialists working with painting and dispensing applications across a variety of industries, including automotive and aerospace. In these areas, industrial robotic automation allows for predictable, controlled movements. It also minimizes exposure of employees to potentially hazardous processes.
A better management of waste materials can also increase productivity by decreasing the amount of unneeded material used.
The System Still Needs people after the installation.
Automation does not eliminate the need for expertise in manufacturing. It transforms the knowledge needed to manage and maintain the manufacturing process.
The employees must know how to safely operate equipment identify abnormal behavior, troubleshoot faults, and conduct the necessary maintenance. Systems and procedures can be adjusted later if the production needs change.
ASA provides training on site in safe operation, programming and troubleshooting, in addition to maintenance of electrical and mechanical systems. The company provides ongoing maintenance and servicing to ensure that equipment is in good working order and wear and tear issues are addressed.
Capacity is the capacity to work more quickly
For Australian producers, expanding capacity doesn’t necessarily mean purchasing a larger building or continually adding workers to repetitive processes. One of the best questions to ask is whether your current manufacturing process can be improved.
ASA has been developing and integrating automation systems since 2002, supporting companies in Australia and also projects around the world. Its method of analysis combines needs and engineering simulation with FANUC integration along with training and servicing.
Automation is not the aim. Any system that is worth investing in should provide a company with quantifiable outcomes, such as increased reliability of production, improved quality, safer methods as well as reduced waste or a higher capacity.