A manufacturer gets an enormous contract. The production requirements for the month increase however, the plant has no room and employees with experience or additional hours in the day. While adding another shift might temporarily aid, it might be a source of new work, supervision, training and requirements for quality control.
This situation highlights a major reason for robots. It’s not just about replacing people with the aid of a machine. In the right application it could alter the way manufacturers make use of the resources they already have.
Image credit: automatedsolutions.com.au
Watch the second-to-second time between products
Inefficiency in manufacturing isn’t always so noticeable. Imagine a worker spending 15 seconds locating a component and then 10 seconds putting it into the material, then several seconds transfer it. On a single part, the difference is insignificant. If repeated thousands of times however the seconds could increase production by a significant amount.
The same is true for the waste materials. In the event of spreading a small amount additional coating or dispensing materials in a huge production run can result in the cost of a large amount.
Companies that are thinking about robotic automation Australia could benefit from analyzing these small routine losses before they decide on the best equipment to buy. The analysis conducted by ASA’s Needs Analysis is designed to uncover bottlenecks and quality issues, waste, as well as other limitations to process which could affect the automation project.
Robots must be able to fit into the process.
Making a choice on a robot is only one option in the engineering process. The system may also need tooling, guarding, controls, sensors, conveyors, fixtures, electronic integration, and connectivity with existing production equipment. Engineers must consider reach, payload and how the robot will move and interact with its surroundings.
ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. Engineers are able to explore configurations for the system and estimate cycles before the system is finally installed in the factory floor. This is particularly helpful when there is a shortage of space or if new robotics require to be incorporated into the existing lines of production.
The importance of repeatability in painting and dispensing
Controlled movement is crucial for certain manufacturing processes. Imagine covering a variety of components. It’s not just about completing the components quickly is the desired outcome. It is crucial to manage the speed, distance, and the movement of every component from the beginning until the very end.
ASA has specialists working with paint and dispensing processes across a variety of industries, including automotive and aerospace. In these settings, industrial robotic automation provides repeatable, programmed movements and reduces exposure of employees to potentially dangerous processes.
Better control of waste material can also contribute to productivity improvements by increasing the quantity of materials used.
Even after installation the system requires people
Automation does not completely eliminate the need for expertise in manufacturing. The knowledge required to operate, maintain and run the process change.
Employees need to be trained to safely use equipment in order to identify any abnormalities or malfunctioning components, and carry out necessary maintenance. Production requirements can also alter, which means that programs and processes may need adjustments later on.
ASA offers on-site training in safe operation, programming troubleshooting, and mechanical and electrical maintenance. It also offers servicing as well as ongoing support to evaluate the condition of the equipment and deal with issues that may arise during the equipment’s operational life.
Capacity is about more than just making work faster
For Australian producers, expanding capacity doesn’t mean purchasing larger buildings or adding workers to repetitive processes. Sometimes the better question is whether or not the existing production process can be redesigned differently.
ASA has been working on and the integration of automation systems since 2002. It has assisted companies in Australia as well as projects internationally. Its method combines the analysis of requirements with engineering, simulations FANUC robotic integration, training, as well as maintenance.
Automation is not to achieve its own goals. A worthwhile system should give an industry a tangible the form of more reliable production and quality, as well as safer procedures, less waste or more capacity from the factory it already operates.
