A large contract is signed by the manufacturer. The monthly production demands rise, but the facility isn’t gaining flooring space, skilled workers or working hours during the day. A temporary increase in production might be possible, but the addition of a shift could introduce new labor requirements training, supervision, and quality control.
These scenarios reveal an important reason for robotic automation. Robotics isn’t only about replacing humans with machines. A good application could change the way manufacturers utilize their production capacity.
Image credit: automatedsolutions.com.au
Check out the seconds between products
Inefficiency in manufacturing doesn’t have to be evident. Imagine a person spending 15 seconds locating a component for 10 seconds, then applying the material and then moving it. The difference might seem small even for a single piece of equipment. Repeated thousands of times but those seconds turn into important production times.
It is the same with the waste materials. 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 could benefit from looking at these small loss events repeatedly before choosing the right equipment. The needs analysis conducted by ASA is designed to identify bottlenecks as well quality issues, waste and other process limitations that might affect an automation plan.
A Robot Must Fit the Process Around It
A robot is just one of many engineering options. The system could also require guarding, tools control, sensors conveyors, fixtures electrical integration, and communications with the existing production equipment. Engineers should consider the payload, reach and range as well as how the robot is going to operate and interact with the surrounding.
ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. Engineers can look at system configurations and estimate cycle times before the finalized system is placed on the factory floor. This is particularly helpful when space is scarce or when new robotics need to be integrated with a production line that is already in place.
Painting and Dispensing demonstrate why the importance of repeatability is evident.
Controlled movement is especially important in certain manufacturing processes. Imagine coating hundreds, or thousands of components. Not just completing components quickly is the desired outcome. The movement, distance, speed, and the application must to be monitored starting from the beginning of the production process until the time of its completion.
ASA is a specialist in painting and dispensing systems across industries including automotive and aerospace. In these environments, industrial robotic automation can allow for repeatable, programmed movements while reducing exposure of employees to physically demanding or potentially dangerous processes.
The reduction of waste and improvement in productivity could be achieved through better control.
The installation of the system isn’t enough. You still need people to take care of it.
Automation can’t replace the manufacturing know-how. It requires new skills to operate and maintain the manufacturing process.
Employees need to be able recognize abnormal behavior and troubleshoot issues, and do the proper maintenance. The demands for production can shift in time, meaning that the processes and programs need to be adapted.
ASA provides training on-site for safe operation, programming troubleshooting, and electrical and mechanical maintenance. The company provides servicing and support for checking the condition of equipment, and dealing with wear throughout the system’s lifetime.
Capacity is more than simply working faster
An increase in capacity for Australian manufacturers does not necessarily mean buying a bigger building or adding additional labor to routine processes. One of the best questions to ask is whether the present manufacturing process can be improved.
ASA has been developing and integrating automation solutions in Australia since 2002. We also provide support for projects across the world. The approach combines needs analysis Engineering, simulation, FANUC robot integration training, servicing, and maintenance.
Automation isn’t the goal. A system that’s worth the gold it’s worth ought to bring tangible benefits to the manufacturer, like higher reliability in production, improved quality methods, less risky processes, and less waste.