A major contract is won by an industrial manufacturer. While the demands for production have increased, the factory isn’t suddenly equipped with more flooring or experienced workers. A second shift may help temporarily, but it may create new labor and training, supervision, and quality-control requirements.
This situation highlights a major reason for robots. Robotics does not only replace people with machines. It could be utilized to transform the way that manufacturers utilize their existing production capacity.
Image credit: automatedsolutions.com.au
Watch the second-to-second time between products
Inefficient manufacturing may not be obvious. For instance, suppose an operator is spending 15 minutes putting a piece of equipment in place, another 10 seconds applying materials, and then several seconds to transfer it to the next operation. The difference may seem insignificant for one component. When repeated thousands of times the seconds are significant production time.
It’s the same for waste material. Multiplying a small amount of extra coating or dispensing materials across a large production run could result in substantial costs.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. ASA’s needs analysis aims to uncover bottlenecks as well quality issues, waste and other processes that could affect an automation project.
The robot has to fit the processes around it.
A robot’s selection is only one engineering decision. It could be necessary to include tooling, guarding and controls, sensors conveyors, fixtures, electrical integration and communication with the current production equipment. Engineers must take into consideration reach and payload when making decisions about how the robot is going to move through its area of work and interact with the environment surrounding it.
The FANUC approach of ASA’s approach to robot automation includes conceptual development and design including CAD Simulation, offline Programming. Engineers can explore system configurations and estimate cycle times before the finished system is installed in the factory floor. It’s particularly useful when there is a small area or new robotics is required to be integrated with a production line.
The importance of repeatability when painting and dispensing
Certain manufacturing processes highlight the benefits of controlled movement particularly well. Imagine coating hundreds or thousands of parts. The final result doesn’t come from finishing each part quickly. From the start of production through the conclusion moving, speed of the machine, the distance and the application have to be managed.
ASA has specialists who work on painting and dispensing solutions across a variety of industries, including automotive and aerospace. In these settings, industrial robotic automation can ensure that the same program is repeated and reduce exposure of employees to physically demanding or potentially hazardous processes.
Better control may also reduce excessive material consumption, thereby contributing to less waste, as well as productivity improvements.
Even after the installation the system requires individuals
Automation can’t replace the manufacturing know-how. It transforms the knowledge needed for operating and maintaining the process.
Employees must be taught to operate equipment in a safe manner in order to identify any abnormalities, troubleshoot faulty components, and carry out necessary maintenance. The production needs can change with time, which means that processes and programs will need to be adjusted.
ASA offers training on-site including programming, safety as well as troubleshooting techniques and electrical and mechanical maintenance. The company also provides regular maintenance and repairs to ensure that the equipment is in good condition and wear and tear issues are dealt with.
Capacity is greater than working faster
In Australia, boosting production capacity is not always about hiring more workers for repetitive tasks or purchasing larger buildings. Sometimes, the more important question is whether the current production process can be engineered differently.
ASA has developed and integrated automation solutions in Australia since 2002. We also assist with projects overseas. The approach is a combination of needs analysis as well as engineering simulation. FANUC integration, training and servicing.
Automation is not the goal. An investment in a system must provide the manufacturer with measurable results, like increased reliability of production, improved quality, safer processes with less waste, or a greater capacity.