A company is awarded a significant contract. The production requirement for each month increases however the facility does not have enough space and has employees with previous experience or additional hours during the day. While adding another shift might temporarily improve the situation, it may be a source of new work as well as training, supervision, and demands for quality-control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics doesn’t just replace humans with machines. The right application can transform how manufacturers use their production capacity.
Watch the second-to-second time between the products
Manufacturing inefficiency doesn’t need to be a major issue. If an operator takes 15 seconds positioning a component after which another 10 seconds are spent applying materials, and then several seconds moving it to the next step. In the case of a single piece, the difference is insignificant. Repeated thousands of times, but those seconds turn into significant production time.
It is the same with scrap material. A small amount of additional coatings or dispensing material over a long production run could lead to an enormous expense.
Before selecting the equipment they will require, companies looking at robotic automation Australia could benefit from analyzing these tiny losses. The analysis conducted by ASA’s Needs Analysis is designed to identify bottlenecks, quality issues, waste, and other processes which could affect the automation project.
Robots have to be integrated into the process.
Selecting a robot is only one of the engineering decisions. It may be necessary to include tooling, guarding and controls, sensors as well as conveyers, fixtures electrical integration, and communication with the existing production equipment. Engineers must take into consideration reach and payload while also determining how the robot will move through its work area and interact with the environment around it.
ASA offers concept development, system design and offline programming as part of its approach to robotic automation. Engineers can look at system configurations and calculate cycles prior to when the finished system is installed on the floor of the factory. It is particularly helpful when there’s a finite space available or when the new robotics requires integration with the production line.
Painting and Dispensing Show Why the importance of repeatability is evident.
The ability to control movement is particularly important in certain manufacturing processes. Imagine applying a coating on hundreds of parts. The final result doesn’t come from finishing each part quickly. From the time of beginning production until the final stage all the movements, speed of the machine, the distance and the application have to be controlled.
ASA’s specialists are experienced in painting and dispensing across different industries like aerospace and automotive. Industrial robotics automation in these areas will allow for repeatable movement as well as limiting the exposure of employees to physically demanding procedures or procedures that could be dangerous.
Controlled better can reduce unnecessary material consumption, contributing to a reduction in waste and productivity gains.
Installation of the system isn’t enough. You will require people to keep it running.
Automatism isn’t a substitute for manufacturing knowledge. Automation alters the knowledge required to operate and maintain the manufacturing process.
Employees must be able to operate equipment in a safe manner identify abnormal behavior as well as troubleshoot issues and conduct the necessary maintenance. Production requirements may also change, meaning programs and processes may need adjustment later.
ASA offers on-site training in safe operation, programming troubleshooting, as well as electrical and mechanical maintenance. The company also provides regular maintenance and service to ensure that equipment is in good repair and wear and tear problems are dealt with.
Capacity is more than working faster
For Australian manufacturers, increasing capacity doesn’t necessarily mean purchasing more space or adding more workers to repetitive processes. Sometimes, the most important thing to consider is whether the existing manufacturing process can be designed differently.
ASA has been developing and integrating automation systems in Australia since 2002. We also provide support for projects overseas. The company’s strategy combines analysis of needs Engineering, simulation, FANUC robot integration, training, and servicing.
Automating for automation’s sake isn’t the goal. A successful system must give the manufacturer something tangible in the form of more reliable production and quality, as well as safer processes, less waste, or a larger capacity for the facility it operates.