A manufacturer is awarded a large contract. Its monthly production needs increase, but the factory hasn’t seen a sudden increase in area for floor, skilled employees, or hours in the day. While adding another shift may temporarily help, it could also create new jobs or supervision, as well as additional training and requirements for quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. It’s not just about replacing a person with an automated machine. A suitable application can alter the way in which manufacturers make use of their production capacity.
Take a look at the seconds that Disappear Between Products
Inefficiency in manufacturing doesn’t have to be dramatic. Imagine that an operator has spent 15 seconds positioning a component, another 10 seconds applying material, and several more seconds moving it to the next step. With a single component the difference is insignificant. These seconds add up when multiplied by thousands.
It’s the same for waste material. In the event of spreading a small amount additional coating or dispensing materials in a huge production run can result in a significant expense.
Businesses considering robotic automation Australia projects could gain from examining these minor regular losses prior to deciding on the equipment they will require. The needs analysis of ASA is designed to pinpoint bottlenecks, inefficiencies, quality issues, and other process constraints that can affect an automation project.
A Robot must be able to integrate the Process Itself
A robot is only one of many engineering options. It may be necessary to add tooling, guarding and controls sensors and conveyers, fixtures, electrical integration and communication with existing production equipment. Engineers should consider the payload and reach while making decisions about how the robot is going to move through its area of work and interact with everything surrounding it.
The FANUC approach of ASA’s approach to robot automation includes concept development, 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 especially useful when space is constrained or when new robotics need to be integrated with a production line that is already in place.
Painting and Dispensing demonstrates why Repetability is Important
Certain manufacturing processes show the importance of controlled movement. Imagine covering hundreds of components. It’s not enough just to finish every component in a short time. The movement, distance, speed, and application need be managed from the start of the production line until the time of its completion.
ASA has experts who work with dispensing applications and paint across various industries, including automotive and aeronautics. In these environments industrial robotic automation can provide regular, programmatic movements and minimizes exposure of employees to physically challenging or potentially dangerous processes.
Better control of waste material can also help improve productivity by increasing the quantity of materials used.
Even after installation, the system still requires people
Automation does not eliminate the need for expertise in manufacturing. The capabilities required to operate, maintain and manage the process are changing.
Employees must be taught to operate equipment with care, identify abnormal behavior, troubleshoot faulty components, and take care of any maintenance that is required. Production requirements can also change, meaning procedures and programs might require modification later.
ASA provides training on site in safe operation, programming, troubleshooting, in addition to maintenance for electrical and mechanical components. They also provide servicing as well as support for evaluating the condition of equipment and taking care to address wear throughout the lifespan of the equipment.
Capacity is about more than Being able to work faster
In Australia, expanding production capacity does not necessarily mean the addition of workers to repetitive tasks or purchasing bigger buildings. It’s often better to ask if the production process can be improved.
ASA has been developing and integration of automation systems since 2002, supporting manufacturers in Australia and also projects internationally. Its method of analysis combines needs as well as engineering simulation. FANUC integration along with training and servicing.
Automation isn’t the main goal. A worthwhile system should give manufacturers something tangible in yield, more stable production with consistent quality, safe processes, less waste, or a greater capacity in the facility it operates.