A manufacturing company wins a big contract. The monthly production demands rise, but the facility isn’t gaining floor space, experienced employees or even hours per daytime. A second shift may help temporarily, but it may also introduce new labor or training, supervision and quality-control demands.
Image credit: automatedsolutions.com.au
This is a crucial need for robotic automation. Robotics does not only mean replacing human workers with machines. If it is used correctly it can alter how producers use the capacity they already have.
Look at the Seconds That disappear between products
Inefficiency in manufacturing isn’t always so evident. Imagine an operator spending 15 seconds looking for a particular component, 10 seconds applying the material and several seconds to transfer it. On one piece the difference isn’t that significant. When repeated a thousand times the second can add significant production time.
The same is true for scrap material. A small amount of excess coating or dispensing material that is 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 could benefit from studying these small loss, repeated ones before they decide on the best equipment to buy. ASA’s needs analysis aims to identify bottlenecks as well problems with quality, waste and other process constraints which could impact an automation project.
A Robot must be able to integrate the Process Around It
Selecting a robot is only one engineering decision. The system will also require tools, guarding and controls, sensors fixtures, conveyors electrical integration, as well as communication with existing production equipment. Engineers need to consider the reach and payload of the robot while determining how the robot will move through its space and interact with everything around it.
The ASA approach to FANUC robot automation is to use concept development and system design including CAD Simulation, offline programming. Engineers can explore system configurations and estimate cycles before the finalized system is placed on the factory floor. This is particularly beneficial in situations where space is not available or when new robotics have to integrate with an established production line.
The importance of repeatability when painting and dispensing
Certain manufacturing processes highlight the importance of controlled movement. Imagine coating hundreds or thousands of components. The end goal isn’t simply completing each component quickly. The distance, movement, speed, and the application must to remain controlled from the start of the production process until the end.
ASA has specialists working with painting and dispensing solutions across industries including 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.
A better management of materials that are discarded can help improve productivity by reducing the amount of unnecessary material consumed.
Even after the installation the system requires individuals
Automatism isn’t a substitute for manufacturing knowledge. It alters the knowledge required to run and maintain the manufacturing process.
Employees need to know how to safely operate equipment, recognize abnormal behavior or malfunctions, then troubleshoot the issue and carry out the correct maintenance. Production requirements may also be changed, which means procedures and programs might require adjustments later on.
ASA offers on-site training in safe operation, programming and troubleshooting, as well as maintenance for electrical and mechanical components. The company provides servicing and support for checking the condition of equipment and taking care to address wear and tear throughout the life of the system.
Capacity refers to more than working faster
The expansion of capacity for Australian manufacturers doesn’t always require the purchase of a larger building or adding additional labor on repetitive processes. The more important question to consider is whether the existing manufacturing process is able to be improved.
ASA has developed and integrated automation solutions in Australia since 2002. We also help with projects across the world. Its approach combines the analysis of requirements, engineering, simulations, FANUC robotic integration training, as well as servicing.
Automation is not the aim. A system that’s worth the gold it’s worth ought to offer tangible benefits to the manufacturer, like better production reliability, better quality, safer processes and less waste.