A manufacturer wins a major contract. The monthly production requirement increases however the facility has no room, employees with experience, or more hours to work during the day. A temporary increase in production may be possible, but an additional shift may bring new demands for labor, training, supervision and quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. It’s not just about replacing a person with the aid of a machine. A suitable application can alter the way manufacturers utilize their capacity to produce.
Watch the second-to-second time between the products
Inefficiency in manufacturing doesn’t have to be dramatic. An operator could spend 15 minutes positioning the item and then 10 seconds putting on materials, and a couple of seconds moving it to the next step. For one part the difference isn’t that significant. If repeated thousands of times these seconds can increase production by a significant amount.
Wasted material is no different. Same goes for the waste material.
Companies considering robot automation Australia projects may benefit from studying these tiny, repeated losses before choosing the right equipment. ASA’s needs analysis is intended to identify bottlenecks, issues with quality, waste as well as other limitations to process that may affect an automation project.
A Robot Has to Fit the Process Itself
A robot is just one of many engineering options. Tools, guardings, controls, sensor, conveyors and fixtures might also be necessary. Engineers must take into consideration the reach of the robot and its payload, and how it interacts with its environment and move about.
ASA offers conceptual development, system design, CAD simulation and offline programming as an element of its approach to FANUC’s robotic automation. The digital simulation allows engineers explore configurations, estimate cycle times and test the system before it becomes functional on the floor of the customer’s facility. This is particularly useful when space is limited or if new robotics require to be integrated with the existing lines of production.
Painting and dispensing show why Repetability is Important
Controlled movement is especially important in some manufacturing processes. Imagine applying a coat to hundreds of parts. Making components faster is the goal. The movement, distance, speed, and application need to be monitored from the beginning of the production line until the end.
ASA is a team of experts working with paint and dispensing application across various industries, including aeronautics and automotive. Industrial robotic automation in these environments can allow for repeatable movements as well as limiting the exposure of workers to physically demanding processes or ones that may risk injury.
Improved control can also cut down on unnecessary material consumption, contributing to a reduction in waste and productivity improvements.
The System Will Still Need Personnel After Installation
Automation doesn’t eliminate the need for manufacturing expertise. It transforms the knowledge needed for operating and maintaining the process.
Employees must be able to recognize unusual behavior and resolve problems, as well as take the necessary maintenance. The production needs can change over time, which means that procedures and protocols will need to be adjusted.
ASA offers training on-site that covers programming, safety troubleshooting, mechanical and electrical maintenance. The company provides continuous maintenance and service to ensure that the equipment is in good condition and wear and tear problems are dealt with.
Capacity is more than just working more quickly
For Australian manufacturers, increasing capacity doesn’t necessarily mean purchasing an additional building or adding workers to repetitive processes. It’s sometimes more beneficial to inquire if the manufacturing process could be redesigned.
ASA has developed and integrated automation systems in Australia since 2002. We also provide support for projects overseas. Its methodology combines the analysis of requirements, engineering, simulations, FANUC robotic integration training, as well as servicing.
Automating just for the sake of it isn’t the goal. A system worthy of the gold it’s worth ought to be able to provide tangible benefits for manufacturers, for example higher reliability in production, improved quality manufacturing processes, and safer ones. It also means less waste.
