A manufacturer wins a major contract. Although the monthly production requirements have grown, the plant does not have an increase in floors or more experienced workers. It is possible to add another shift temporarily, but it could be a source of new labor and training, supervision, and quality-control requirements.
This kind of situation reveals an important function of robotic automation. Robotics goes beyond replacing people with machines. If it is used correctly it can alter how manufacturers use the production capacity they already have.
Image credit: automatedsolutions.com.au
Take a look at the time intervals between the products
Manufacturing inefficiency doesn’t have to be evident. A worker could spend 15 minutes positioning the item and then 10 seconds putting on materials, and then a few seconds more to move it onto the next stage. The difference might seem small for one component. Repeated thousands of times, these seconds can turn into important production times.
The same applies to wasted material. The addition of a tiny amount of additional coating or dispensing materials in a huge production line can lead to a significant expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. The needs analysis conducted by ASA is designed to pinpoint bottlenecks, as well waste, quality issues and other limitations to process that could impact an automation project.
The robot needs to be able to accommodate the process around it
A robot’s selection is only one option in the engineering process. The system could also require guarding, tools, controls, sensors fixtures, conveyors, electrical integration, and communication with the existing production equipment. Engineers must take into consideration reach and payload while also determining how the robot is going to move through its space and interact with the environment around it.
The ASA approach to FANUC robot automation encompasses conceptual development and design along with CAD Simulation and offline Programming. The digital simulation lets engineers analyze configurations, estimate cycles times and test the system prior to making it operating on the floor of a customer’s premises. It’s especially useful when there is a small area or new robotics has to integrate with an existing production line.
Painting and Dispensing demonstrate why Repetability is Important
Some manufacturing processes demonstrate the importance of controlled motion especially well. Imagine covering hundreds of components. The ability to finish components in a short time is the ideal outcome. It is important to control the speed, distance and movement of each part from the beginning to the at the very end.
Our specialists have experience painting and dispensing across industries such as automotive and aerospace. Industrial robotic automation in these settings allows for reproducible movements as well as limiting the exposure of workers to physical demands or those that could cause harm.
A better control system can also help reduce the amount of material used, which can lead to a reduction in waste and productivity improvement.
The System Still Needs People After Installation
Automating doesn’t completely eliminate the requirement for knowledge in manufacturing. It requires new skills to run and maintain the manufacturing process.
Employees must be instructed to operate equipment in a safe manner and to recognize abnormal behavior and troubleshoot malfunctioning components and take care of any maintenance that is required. Processes and programs can be adjusted later if production requirements change.
ASA offers training on-site including programming, safety troubleshooting, mechanical and electrical maintenance. It also offers servicing and ongoing support to check the condition of equipment and address wear and tear over the course of its operating duration.
Capacity is more than just working faster
A rise in capacity for Australian manufacturing companies doesn’t mean buying a bigger building or adding more labor to routine processes. Sometimes, the most important thing to consider is whether or not the existing production process can be engineered differently.
ASA has been creating and integrating automation systems since 2002, supporting manufacturers in Australia and projects internationally. The method is based on the analysis of requirements, engineering, simulations, FANUC robotic integration, training, as well as maintenance.
Automation is not the only goal. An investment-worthy system should offer a manufacturer measurable results, which include more reliable production, higher quality, safer processes with less waste, or a greater capacity.
