A company is awarded a significant contract. Monthly production requirements are increased, but the manufacturing facility hasn’t seen a sudden increase in floors, employees with experience or working hours during the daytime. The addition of a second shift could help in the short term, but it could create new labor as well as training, supervision and quality-control regulations.
Such situations highlight the purpose behind robotic automation. Robotics is not just replacing humans with machines. If it is used correctly, it can change how companies use the capacity they already have.
Image credit: automatedsolutions.com.au
Check out the Seconds that Aren’t able to be found between the products
Inefficiency in manufacturing isn’t always so evident. For instance, suppose an operator is spending 15 seconds arranging a part, another 10 seconds applying materials, and then several seconds moving it to the next step. It may appear to be a small difference for a single component. If repeated thousands of times, the seconds are significant production time.
Material that has been wasted isn’t different. A small amount of extra coating or dispensing material that is multiplied throughout a production run that is high-volume could result in a significant expense.
Companies considering robot automation Australia projects may benefit from examining these small regular losses prior to deciding what equipment they need. The needs analysis conducted by ASA is designed to pinpoint bottlenecks, as well problems with quality, waste and other process limitations that might affect an automation plan.
Robots have to integrate into the process.
Selecting a robot is only one engineering decision. The system might also require tooling, guarding control, sensors conveyors, fixtures electrical integration, as well as communication with the existing production equipment. Engineers must consider the range, payload, and how the robot will move and interact in its environment.
ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. Engineers can investigate system configurations and estimate the number of cycles required before the finalized system is placed on the floor of the factory. It is particularly helpful in situations where there is a restricted space available or when the new robotics has to integrate with the production line.
It is crucial to have repeatability in painting and dispensing
Controlled movement is especially important in some manufacturing processes. Imagine applying a coating to hundreds of parts. Making components faster is the goal. It is important to control the speed, distance, and movement of each component from beginning to at the very end.
ASA is a team of experts working with dispensing applications and paint across various industries, including aeronautics and automotive. In these settings, industrial robotic automation can provide repeatable, programmed movements and reduces exposure of employees to physically challenging or potentially dangerous processes.
Better control of the waste material can also aid in productivity improvement by cutting down on the amount of waste materials used.
The System Still Needs People Even After Installation
Automation doesn’t substitute for manufacturing expertise. It alters the knowledge required to operate and maintain the process.
Employees must be instructed to safely use equipment and to recognize abnormal behavior or malfunctioning components, and carry out necessary maintenance. Processes and programs can be modified later on if the production needs alter.
ASA provides training on site in safe operation, programming and troubleshooting, in addition to mechanical and electrical maintenance. The company provides continuous maintenance and repairs to ensure that the equipment is in top order and wear and tear issues are dealt with.
Capacity is more than just making work faster
An increase in capacity for Australian manufacturers does not necessarily require the purchase of a larger building or adding more labor on repetitive processes. Sometimes, the best question is whether the existing manufacturing process can be designed differently.
ASA has been developing and integration of automation systems since 2002, supporting companies in Australia as well as projects internationally. Its strategy combines analysis of needs along with engineering simulation FANUC integration, training and servicing.
Automation is not the goal. Any system that is worth investing in must provide the manufacturer with measurable outcomes, such as increased reliability of production, improved quality, safer procedures with less waste, or a greater capacity.