A company is awarded an important contract. The monthly production needs increase however, the plant doesn’t have more space and employees with experience or additional hours in the daytime. While adding another shift might temporarily help, it could be the cause of additional labor as well as training, supervision, and quality-control needs.
Image credit: automatedsolutions.com.au
These situations reveal a very crucial reason for robot automation. Robotics goes beyond replacing people with machines. It could be utilized to transform the way that manufacturers utilize their existing capacity for production.
Check out the seconds between products
Inefficient manufacturing is not always apparent. An operator could spend 15 seconds positioning the component after which 10 seconds are spent applying materials, and then a few seconds to move it to the next step. In the case of a single piece, it’s a small difference. If repeated thousands of times, these seconds can turn into an enormous amount of production time.
The same is true for waste material. A tiny amount of leftover coating or dispensing material multiplied throughout a production run that is high-volume can become a meaningful expense.
Companies considering robot automation Australia projects can benefit from examining these small regular losses prior to choosing the right equipment. ASA’s needs analysis is intended to find bottlenecks, problems with quality, waste and other constraints to the process that can affect an automation project.
The robot needs to be able to accommodate the system around it.
Making a choice on a robot is only one option in the engineering process. The system will also require guarding, tooling and controls, sensors fixtures, conveyors, electrical integration, as well as communication with the existing production equipment. Engineers should take into consideration reach, payload and how the robot is going to be able to move and interact within its environment.
ASA’s approach for FANUC robot automation is to use the development of concepts and systems, CAD Simulation, and offline programming. Digital simulation allows engineers to investigate configurations and estimate time-to-market before the system is operational at the factory floor of the customer’s. This is particularly beneficial when space is constrained or if new robotics are required to integrate with an established production line.
Paint and Dispensing demonstrates why Replicability is Important
Certain manufacturing processes highlight the importance of controlling movements. Imagine covering a variety of components. It’s not enough to finish each component in a short time. From the beginning of production all the way to the finish moving, speed, distance and application must be managed.
ASA has specialists who work on painting and dispensing solutions 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.
An improved control over materials that are discarded can aid in productivity improvement by reducing the amount of unnecessary material that is consumed.
The installation of the system isn’t enough. You still need people to keep it running.
Automation doesn’t eliminate the need for expertise in manufacturing. It alters the knowledge required to run and maintain the manufacturing process.
Employees must be able to spot abnormal behavior and solve problems, as well as perform the appropriate maintenance. Production requirements can change over time, which means that the processes and programs have to be modified.
ASA provides on-site training covering programming, safe operation, troubleshooting, and electrical and mechanical maintenance. The company offers ongoing maintenance and repairs to ensure that equipment is in good order and wear and tear issues are addressed.
Capacity is more than just getting faster work done
For Australian producers, expanding capacity doesn’t always mean purchasing an additional building or adding labor to repetitive processes. It’s sometimes more beneficial to ask if the production process can be improved.
ASA has created and integrated automation solutions in Australia since 2002. We also provide support for projects overseas. Its method combines analysis of needs and engineering, simulations, FANUC robotic integration and training as well as maintenance.
Automating for automation’s sake isn’t the goal. A worthwhile system should give the manufacturer something tangible in terms of increased reliability that is consistent in quality, more secure methods, less waste or a larger capacity for the existing factory.
