A manufacturing company gets an important contract. The production requirements for the month increase however, the plant does not have enough space and has employees with previous experience or extra hours during the daytime. An increase in production for a short period is possible, but an additional shift may bring 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 machines. It’s a tool that can modify the methods that manufacturers employ to use their current production capacity.
Watch the second-to-second time between products
Manufacturing inefficiency doesn’t have to be evident. Imagine a worker spending 15 seconds looking for a particular component, 10 seconds applying the material and several seconds transferring it. For a single component, the difference in time is not significant. If repeated thousands of times however the seconds could result in significant production delays.
This is also true of wasted material. The addition of a tiny amount of additional coatings or dispensing material across a large production line can lead to an enormous expense.
Before making a decision on the equipment they will require, companies looking at robotic automation Australia can benefit by analyzing the small loss. ASA’s analysis of requirements is designed to uncover problems with quality and bottlenecks as also any other limitations within a project.
A Robot Must Fit the Process Itself
A robot’s selection is only one engineering decision. It may be necessary to add tooling, guarding and controls, sensors as well as conveyers, fixtures electrical integration and communication with the existing production equipment. Engineers should think about the 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 based on concept development and system design, CAD Simulation, and offline Programming. The digital simulation allows engineers to examine configurations, estimate cycle times, and evaluate the system prior to making it in operation on the floor of the customer’s. This is especially helpful when there are space constraints or when a new robot needs to be incorporated into the existing lines of production.
The importance of consistency in painting and dispensing
Certain manufacturing processes illustrate the importance of controlling movements. Imagine coating hundreds or thousands of components. It’s not enough to finish each part quickly. It’s crucial to regulate the speed, distance and movement of each piece from the beginning until the close of the process.
ASA has experts working on painting and dispensing solutions across a variety of industries, including automotive and aerospace. In these areas, industrial robotic automation can provide regular, programmatic movements and reduces employee exposure to physically challenging or potentially hazardous processes.
The reduction in waste and the increase in productivity is possible by better control.
Installation of the system isn’t enough. You still need people to keep it running.
Automation doesn’t eliminate the need for skilled manufacturing. The capabilities required to operate, maintain and manage the process are changing.
Employees should be trained to use equipment safely in order to identify any abnormalities and troubleshoot malfunctioning components and complete any necessary maintenance. The production needs can change as time passes, which means that procedures and protocols will need to be adapted.
ASA provides training on site in programming, safety, troubleshooting and electrical and mechanical maintenance. The company also provides servicing and support on a regular basis to assess the condition of equipment and to address wear over the system’s operating time.
Capacity goes beyond just getting faster work done
An increase in capacity for Australian manufacturers doesn’t always involve buying a bigger facility or adding more labor on repetitive processes. The best question to ask is whether the existing manufacturing process could be improved.
ASA has been working on and the integration of automation solutions since 2002. It has assisted companies in Australia as well as projects in other countries. The company’s strategy combines analysis of needs with engineering, simulation, FANUC robot integration Training, and servicing.
Automation is not for its own sake. A system that is worthy of the gold it’s worth must offer tangible benefits to manufacturers, for example higher reliability in production, improved quality methods, less risky processes, and less waste.