A manufacturer wins a major contract. The production requirements for the month increase but the company doesn’t have more space or employees who have experience or more hours to work during the day. An increase in production for a short period could be possible, however the addition of a shift could introduce new demands for labor, training, supervision and quality control.
These kinds of situations reveal the purpose behind robotic automation. Robotics doesn’t just mean replacing humans with machines. In the right application, it can change how producers use the capacity they have.
Image credit: automatedsolutions.com.au
Take a look at the seconds that disappear between products
Manufacturing inefficiency doesn’t need to be a major issue. Imagine that an operator has spent 15 minutes putting a piece of equipment in place for 10 seconds, then another 10 seconds applying materials, and then several seconds transferring it to the next process. It may appear to be a small difference for a single part. When repeated thousands of times however these seconds can result in significant production delays.
The waste material that is discarded is not different. A small amount of excess coating or dispensing material that is multiplied across a high-volume production run can become a meaningful expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. ASA’s analysis of requirements is designed to pinpoint problems with quality and bottlenecks, as also any other limitations within a project.
A Robot Must Fit the Process Itself
A robot is one of many engineering choices. The system may also need tools, guarding, controls, sensors fixtures, conveyors electrical integration, as well as communication with existing production equipment. Engineers should think about the range, payload, and how the robot will be able to move and interact within the environment.
ASA provides concepts development, design, CAD simulation and offline programming as part of its strategy to FANUC robotic automation. The digital simulation allows engineers to analyze configurations, estimate cycles time and allow them to test the system prior to it becoming operational on the customer’s floor. This is particularly helpful when there are space constraints or when a new robot needs to be integrated into the existing lines of production.
Painting and dispensing show why the importance of repeatability is evident.
Certain manufacturing processes highlight the benefits of controlled movement particularly well. Imagine coating hundreds or thousands of components. The end goal isn’t simply finishing each part quickly. From the beginning of production to the end the speed, movement, distance and application must be controlled.
ASA has specialists who work on painting and dispensing systems across a variety of industries, including automotive and aerospace. Industrial robotic automation in these industries allows for repeatable motions as well as limiting the exposure of workers to physical demanding processes or procedures that could risk injury.
The reduction in waste and the improvement in productivity could be achieved through better control.
Even after installation, the system still requires people
Automation doesn’t eliminate the need for manufacturing knowledge. It requires new skills to manage and maintain the process.
Employees must be able to spot abnormal behavior and solve problems, as well as take the necessary maintenance. Processes and programs are able to be changed later if the production needs alter.
ASA provides on-site training in safe operation, programming, troubleshooting. It also offers mechanical and electrical maintenance. They also provide servicing as well as support for evaluating the condition of equipment and addressing wear throughout the lifespan of the equipment.
Capacity is more than just working more quickly
In Australia, boosting production capacity does not necessarily mean adding more employees to repetitive jobs or purchasing larger structures. Sometimes, the more important question is whether the present production process can be redesigned differently.
ASA has been working on and integrating automation systems in Australia since 2002. We also support projects across the world. The method is based on the analysis of requirements, engineering, simulations, FANUC robotic integration and training and also servicing.
It’s not about automation for the sake of it. A successful system must give the manufacturer something tangible in terms of increased reliability that is consistent in quality, more secure processes, less waste, or a larger capacity for the factory it already operates.