A large contract is signed by the manufacturer. The monthly production demands increase, but the factory isn’t gaining floor space, experienced employees or working hours during the day. An increase in production for a short period is possible, but the addition of a shift could introduce new labor requirements, training, supervision and quality control.
Image credit: automatedsolutions.com.au
This kind of situation reveals an important function of robotic automation. Robotics doesn’t just replace humans with machines. If used properly it can transform the way companies use the capacity they have.
Check out the seconds that disappear between the products
Manufacturing inefficiency doesn’t have to be dramatic. Imagine that an operator has spent 15 minutes putting a piece of equipment in place, another 10 seconds applying materials, and then several seconds transferring it onto the next task. It may appear to be a small difference for a single component. Those seconds add up when multiplied by thousands.
The same is true for wasted material. In the event of spreading a small amount extra coating or dispensing materials over a long production run could result in substantial costs.
The companies that are considering robotic automation Australia could benefit from analyzing these small repeated losses prior to decide which equipment to buy. The needs analysis of ASA is designed to identify bottlenecks, inefficiencies, quality issues, and other constraints to the process that can affect an automation project.
The robot needs to be able to accommodate the process around it
Robots are just one of the many engineering choices. Controls, guardings and tooling, sensor, conveyors and fixtures could also be needed. Engineers must take into consideration reach and payload while also determining how the robot will move about its workspace and interact with the environment surrounding it.
ASA’s approach to FANUC robot automation encompasses conceptual development and design as well as CAD Simulation and offline programming. Digital simulation allows engineers to investigate configurations and estimate durations of the cycle before the system is operating at the customer’s factory floor. This is particularly helpful in situations where space is not available or new robotics must integrate into an existing production line.
Painting and dispensing show why Repetability is Important
Controlled movement is essential in some manufacturing processes. Imagine coating hundreds or thousands of parts. It’s not enough just to finish each part in a short time. It is important to control the speed, distance and movement of each piece from beginning to very end.
The experts at ASA are proficient in dispensing and painting across various industries such as aerospace and automotive. In these environments, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially hazardous processes.
A better control of waste materials can also increase productivity by decreasing the amount of unneeded materials used.
Even after installation, the system still requires people
Automation doesn’t eliminate the need for skilled manufacturing. The capabilities needed to manage, maintain, and manage the process are changing.
Employees need to be able recognize unusual behavior and resolve issues, and perform the appropriate maintenance. Processes and programs are able to be changed later if production requirements change.
ASA provides training on site in safe operation, programming, troubleshooting, as well as maintenance of electrical and mechanical systems. They also provide servicing as well as support for evaluating equipment condition, and addressing wear throughout the system’s lifetime.
Capacity is more than working more quickly
For Australian producers, expanding capacity doesn’t mean purchasing larger buildings or increasing the amount of labor required to perform repetitive tasks. Sometimes, it is better to ask if the production process could be redesigned.
ASA has been developing and integrated automation solutions since 2002. It supports companies in Australia as well as international projects. The method is based on the analysis of requirements, engineering, simulations, FANUC robotic integration, training, and also servicing.
Automating for automation’s sake isn’t the objective. An investment in a system should provide a company with quantifiable results, like increased reliability of production, improved quality, more secure procedures with less waste, or a greater capacity.