A manufacturer wins a major contract. While the requirements for monthly production have increased, the factory isn’t suddenly equipped with more floor space or experienced employees. A temporary increase in production might be possible, but adding another shift can bring new demands for labor as well as training, supervision, and quality control.
Situations like this reveal an important function of robotic automation. Robotics does not only mean replacing human beings with machines. The right application can transform the way manufacturers utilize their capacity to produce.
Image credit: automatedsolutions.com.au
Check out the seconds between the products
Inefficiency in manufacturing doesn’t have to be a major issue. An operator may spend 15 minutes positioning the item and then 10 seconds putting on materials, then a few more seconds moving it onto the next stage. On one piece the difference isn’t that significant. Those seconds add up when multiplied by thousands.
The same is true for wasted material. A tiny amount of leftover coating or dispensing material that is multiplied over a large-scale 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. The analysis of needs by ASA aims to identify bottlenecks as well waste, quality issues and other process constraints which might affect an automation plan.
The robot should fit the system around it.
Robots are just one of many engineering decisions. The system could also require tooling, guarding devices, controls, conveyors, fixtures, electronic integration, and connectivity with existing production equipment. Engineers should take into consideration the range, payload, and how the robot will move and interact with its environment.
The ASA approach to FANUC robot automation includes the development of concepts and systems along with CAD Simulation and offline programming. Engineers can explore system configurations and estimate the number of cycles required before the system is finally installed in the factory floor. It’s particularly useful when there’s a finite space available or when the new robotics needs to integrate with the production line.
Painting and Dispensing Show Why the importance of repeatability is evident.
The ability to control movement is particularly important for certain manufacturing processes. Imagine coating hundreds, or thousands of parts. Not just completing components quickly is the ideal outcome. It is important to control the speed, distance and movement of each piece from beginning to very end.
ASA has experts who work with dispensing applications and paint across all industries, including automotive and aeronautics. In these settings industrial robotic automation could ensure that the same program is repeated while also reducing employee exposure to physically demanding or dangerous processes.
Better control of waste material can also help improve productivity by increasing the quantity of materials used.
Installing the system is not enough. You still need people to manage it.
Automation doesn’t substitute for manufacturing expertise. It requires new skills to run and maintain the manufacturing process.
Employees need to be trained to safely use equipment as well as to spot abnormal behavior and troubleshoot malfunctioning components and take care of any maintenance that is required. The demands for production can shift in time, meaning that processes and programs will have to be modified.
ASA offers on-site training in programming, safety, troubleshooting and electrical and mechanical maintenance. The company provides ongoing maintenance and servicing to ensure that the equipment is in good order and wear and tear issues are dealt with.
Capacity is about more than the ability to work faster
For Australian manufacturers, increasing capacity doesn’t always mean purchasing a larger building or continually adding workers to repetitive processes. Sometimes, the more important question is whether or not the existing manufacturing process could be designed differently.
ASA has been developing and integrated automation solutions since 2002. It works with manufacturers in Australia, as well as international projects. The method is based on the analysis of requirements and engineering, simulations, FANUC robotic integration training, and also servicing.
Automation is not the goal. A system that’s worth the gold it’s worth ought to be able to provide tangible benefits for the manufacturer, like better production reliability, better quality process, more secure processes and less waste.