A manufacturer is awarded a large contract. Although the monthly production requirements have grown, the plant isn’t suddenly equipped with more flooring or experienced workers. While adding another shift might temporarily improve the situation, it may also bring new labor in the form of supervision, training, or demands for quality-control.
These scenarios reveal an crucial reason for robot automation. Robotics doesn’t just mean replacing human beings with machines. The right application can transform the way that manufacturers use their production capacity.
Image credit: automatedsolutions.com.au
Take a look at the seconds that Change Between Products
Manufacturing inefficiency doesn’t need to be dramatic. If an operator takes 15 seconds positioning a component for 10 seconds, then another 10 seconds applying material, and then a few seconds to transfer it onto the next task. For a single component, the difference in time is not significant. Repeated thousands of times these seconds can turn into important production times.
The same is true for wasted material. A tiny amount of surplus coating or dispensing material multiplied over a large-scale production run could result in a significant expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. ASA’s needs analysis is designed to pinpoint bottlenecks, inefficiencies, quality issues, as well as other limitations to process that can affect an automation project.
The robot should fit the processes around it.
The choice of a robot is just one of the engineering decisions. Controls, guardings and tooling sensors, conveyors, and fixtures are also required. Engineers need to consider the robot’s reach and payload as well as how it interacts with its environment and how it will move.
ASA’s approach for FANUC robot automation is based on conceptual development and design as well as CAD Simulation and offline programming. The digital simulation allows engineers explore configurations, estimate cycle times, and evaluate the system before it is in operation on the floor of the customer’s. It is particularly helpful when there’s a finite amount of space, or when the new robotics has to integrate with the production line.
The importance of repeatability when painting and dispensing
Some manufacturing processes illustrate the importance of controlled movement particularly well. Imagine coating hundreds, or thousands of components. The end goal isn’t simply complete each component at a rapid pace. From the time of beginning production to the end the speed, movement of the machine, the distance and the application have to be controlled.
Our specialists have experience dispensing and painting across various industries such as automotive and aerospace. In these settings, industrial robotic automation provides repeatable, programmed movements and minimizes exposure of employees to physically challenging or potentially dangerous processes.
A better control system can also help reduce unnecessary material consumption, contributing to a decrease in waste as well as productivity improvement.
The System Will Still Need People After Installation
Automation doesn’t substitute for manufacturing expertise. Automation alters the knowledge required for maintaining and operating the manufacturing process.
Employees need to be trained to operate equipment with care, identify abnormal behavior as well as troubleshoot components that are malfunctioning and complete any necessary maintenance. The needs for production may change with time, which means that programs and processes will need to be adjusted.
ASA offers training on site that covers safe operation, programming, troubleshooting, as well as electrical and mechanical maintenance. The company also provides regular maintenance and repairs to ensure that equipment is in top repair and wear and tear problems are dealt with.
Capacity is about more than the ability to work faster
A rise in capacity for Australian manufacturers doesn’t necessarily involve buying a bigger facility or adding more labor on repetitive processes. Sometimes, the best question is whether or not the existing manufacturing process could be designed differently.
ASA has been developing and integrating automation systems in Australia since 2002. We also assist with projects across the world. Its strategy combines analysis of needs as well as engineering simulation. FANUC integration, training and servicing.
Automating just for the sake of it isn’t the objective. A system worthy of its weight in gold should provide measurable benefits to the manufacturer, like greater reliability, higher quality, safer processes and less waste.