A manufacturer is awarded a large contract. The production requirement for each month increases however, the plant doesn’t have more space or employees who have experience or additional hours in the day. An increase in production for a short period could be possible, however adding another shift can introduce new requirements for labor education, supervision, training and quality control.
These situations reveal a very significant reason to use robotics automation. Robotics goes beyond replacing people with machines. If used properly it can transform the way manufacturers use the production capacity they already have.
Image credit: automatedsolutions.com.au
Have a look at the minutes that vanish between the products
Inefficiency in manufacturing doesn’t have to be a major issue. An operator could spend 15 minutes positioning the item and then 10 seconds putting on materials, and then a few more seconds moving it onto the next stage. In the case of a single piece, it’s a small difference. If repeated a thousand times the seconds could increase production by a significant amount.
It is the same with wasted material. A small amount of excess coating or dispensing material multiplied across a high-volume 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 uncover bottlenecks and inefficiencies, quality issues, as well as other limitations to process which could affect the automation project.
Robots need to be able integrate into the process.
Making a choice on a robot is only one of the engineering decisions. It might be necessary to incorporate tooling, security and controls, sensors, conveyers, fixtures, electrical integration, and communication with the existing production equipment. Engineers should consider the robot’s reach and payload, as well as how it interact with its surroundings and move about.
The ASA approach to FANUC robot automation includes concept development and system design, CAD Simulation, and offline programming. Digital simulation allows engineers to examine configurations and estimate the cycle times before the completed system is operating on the customer’s factory floor. This is especially helpful when there is a shortage of space or if new robotics need to be integrated with existing production lines.
The importance of repeatability when painting and dispensing
Certain manufacturing processes illustrate the importance of controlled movement. Imagine coating hundreds, or thousands of parts. It’s not enough to complete each piece in a short time. It is crucial to manage the speed, distance, and movement of each component from the beginning until the close of the process.
ASA has specialists who work in the field of dispensing and painting across various industries, including automotive and aeronautics. In these environments industrial robotic automation can provide repeatable, programmed movements and minimizes exposure of employees to physically challenging or potentially dangerous processes.
A better control of waste material can also help improve productivity by cutting down on the amount of waste material that is consumed.
The System Will Still Need People After Installation
Automation doesn’t eliminate the requirement for manufacturing knowledge. Automation alters the knowledge required to manage and control the process.
Employees need to know how to operate equipment in a safe manner and recognize any abnormalities, troubleshoot faults, and take care of maintenance. The production requirements can also be changed, which means programs and processes may need adjustment later.
ASA offers on-site training in safe operation, programming and troubleshooting, as well as maintenance for electrical and mechanical components. The company also provides regular maintenance and services to ensure that the equipment is in good order and wear and tear issues are taken care of.
Capacity is more than working more quickly
A rise in capacity for Australian manufacturers doesn’t always mean buying a bigger building or adding additional labor to repeat processes. The better question to ask is whether the current manufacturing process can be improved.
ASA has been designing and integrated automation solutions since 2002. It provides support to the manufacturing industry in Australia as well as international projects. Its method of analysis combines needs, engineering simulation, FANUC integration as well as training and maintenance.
Automation is not the only goal. An investment in a system will provide a manufacturer with tangible results, like increased reliability of production, improved quality, more secure procedures with less waste, or a greater capacity.