A manufacturing company wins a big contract. Production requirements for the month increase, yet the factory isn’t gaining flooring space, skilled workers or even hours per day. A temporary increase in production may be possible, but the addition of a shift could introduce new demands for labor education, supervision, training and quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics doesn’t just mean replacing human beings with a machine. In the right application, it can change how companies use the capacity they have.
Look at the Seconds That Aren’t able to be found between the products
Inefficient manufacturing isn’t always obvious. An operator could spend 15 minutes positioning the item, then 10 seconds applying materials, and a couple of seconds moving it to the next step. On one aspect, the difference seems insignificant. When repeated thousands of times however the seconds could add significant production time.
It is the same with wasted material. A tiny amount of surplus coating or dispensing material that is multiplied over a large-scale production run can become a meaningful expense.
Companies looking into robot automation Australia projects can benefit from looking at these small regular losses prior to making a decision on the equipment they require. The needs analysis conducted by ASA is designed to uncover bottlenecks as well waste, quality issues and other limitations to process that can affect the automation project.
The robot must fit the processes around it.
The choice of a robotics system is a single decision in engineering. It might be necessary to incorporate tooling, security and controls, sensors as well as conveyers, fixtures electronic integration and communication with the current production equipment. Engineers should consider the robot’s reach and payload, and how it interacts with its environment and move about.
ASA provides conceptual development, system design, CAD simulation, and offline programming as part of its plan to FANUC’s robotic automation. The digital simulation allows engineers examine configurations, estimate cycle times, and evaluate the system before it becomes operating on the floor of a customer’s premises. It’s especially useful when there is a small amount of space or the new robotics requires integration with an existing production line.
Dispensing and painting demonstrate why Replicability is Important
Controlled movement is crucial in certain manufacturing processes. Imagine coating hundreds, or thousands of components. The ability to finish components in a short time is the ideal outcome. The motion, distance, speed, and application have be controlled at the beginning of the production process to the end.
ASA is a specialist in paint and dispensing processes across various industries, including automotive and aerospace. Industrial robotics automation in these areas allows for reproducible movements while limiting exposure of employees to physically demanding procedures or those that could be hazardous.
A better management of waste material can also help improve productivity by increasing the quantity of material that is consumed.
The System Still Needs People Even After Installation
Automation can’t replace the manufacturing know-how. Automation changes the skills needed to operate and maintain the process.
Employees need to be trained to safely use equipment, identify abnormal behavior and troubleshoot malfunctioning components and complete any necessary maintenance. The production needs can change in time, meaning that processes and programs will have to be modified.
ASA offers on-site training in programming, safe operation, troubleshooting, as well as mechanical and electrical maintenance. The company also provides maintenance and assistance for assessing the condition of equipment and addressing wear throughout the system’s lifetime.
Capacity is the capacity to work more quickly
For Australian manufacturers, increasing capacity doesn’t necessarily mean purchasing larger buildings or adding more workers to repetitive processes. One of the best questions to ask is whether your current manufacturing process can be improved.
ASA has been working on and integrating automation solutions in Australia since 2002. We also support projects in other countries. Its method of analysis connects needs, engineering, simulation, FANUC robot integration training, servicing, and maintenance.
Automation for the sake of automation isn’t a goal. An investment in a system should offer a manufacturer measurable results, including better production reliability, higher quality, safer processes with less waste, or a greater capacity.
