A manufacturing company gets a large contract. The production requirement for each month increases but the company has no room or employees who have experience or extra hours during the daytime. A second shift may help temporarily, but it could also introduce new labor as well as training, supervision and quality control requirements.
Image credit: automatedsolutions.com.au
This kind of situation reveals an important function of robotic automation. It’s not just about replacing humans with machines. In the right application, it can change how manufacturers use the production capacity they have.
Take a look at the time intervals between the products
Inefficiency in manufacturing doesn’t have to be noticeable. For instance, suppose an operator is spending 15 seconds positioning a component, another 10 seconds applying materials, and then several seconds to transfer it onto the next task. For a single component, the difference is insignificant. When repeated thousands of times these seconds can add significant production time.
Same goes for waste material. A tiny amount of surplus coating or dispensing material that is multiplied throughout a production run that is high-volume can result in an expense that is significant.
Companies that are thinking about robotic automation Australia will benefit from looking at these small routine losses before they decide on the best equipment to buy. The needs analysis conducted by ASA is designed to find bottlenecks and the quality of work, waste and other processes that could impact an automation project.
Robots should be able to work with the system.
Robots are just one of many engineering choices. The system might also require tooling, guarding and controls, sensors, conveyors, fixtures, electronic integration, and connectivity with the existing production equipment. Engineers must consider reach and payload when making decisions about how the robot will move through its space and interact with the environment around it.
ASA offers concept development, system design and offline programming as part of its method of robotic automation. The digital simulation allows engineers explore configurations, estimate cycle times, and to test the system before it is operating on the floor of a customer’s premises. It is particularly helpful when there is a small space available or when the new robotics has to integrate with the production line.
Painting and dispensing show why Repeatability Matters
Some manufacturing processes illustrate the importance of controlled movement especially well. Imagine coating hundreds of components. Making components faster is the desired outcome. From the time of beginning production until the final stage moving, speed and distance must be controlled.
ASA has specialists who work on painting and dispensing applications 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 the waste material can also contribute to productivity improvements by reducing the amount of unnecessary materials used.
Even after installation the system will still require people
Automation does not eliminate the need for expertise in manufacturing. The capabilities required to manage, maintain, and control the process evolve.
The employees must know how to operate equipment in a safe manner and recognize any abnormalities or malfunctions, then troubleshoot the issue and perform appropriate maintenance. Production requirements can change with time, which means that processes and programs will need to be adapted.
ASA provides on-site training in safe operation, programming and troubleshooting, as well as electrical and mechanical maintenance. The company also provides servicing and support on a regular basis to assess equipment condition and address wear over the system’s operating life.
Capacity is the capacity to work more quickly
In Australia, expanding production capacity doesn’t always mean adding more employees to repetitive jobs or purchasing larger structures. The best question to ask is whether the existing manufacturing process can be improved.
ASA has developed and integrated automation solutions in Australia since 2002. We also provide support for projects abroad. Its strategy combines analysis of needs as well as engineering simulation. FANUC integration training, and service.
The objective isn’t automation just for the sake of automation. An investment in a system should offer a manufacturer measurable results, like greater reliability in production, better quality, safer methods and reduced waste, or an increase in capacity.