A large contract is signed by a manufacturer. Production requirements for the month increase, but the factory hasn’t seen a sudden increase in floor space, experienced employees or even hours per day. A second shift may help temporarily, but it can also introduce new labor and training, supervision, and quality-control requirements.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics does not only replace people with machines. It is able to modify the methods that manufacturers employ to use their production capacity.
Check out the Seconds that disappear between products
Inefficiency in manufacturing doesn’t have to be noticeable. A worker may take 15 seconds positioning the component, then 10 seconds applying materials, then a couple of seconds moving it onto the next stage. On a single part, the difference is minimal. When repeated thousands of times however, these seconds can increase production by a significant amount.
The waste material that is discarded is not different. A small amount of extra coating or dispensing materials over a long production line can lead to a significant expense.
Companies considering robotic automation Australia projects may benefit from studying these tiny, repeated losses before choosing the right equipment. ASA’s analysis of requirements is designed to reveal bottlenecks and quality issues as in addition to any other limitations in a plan.
A Robot Has to Fit the Process Itself
The choice of a robotics system represents only one decision in engineering. Tooling, guardings, controls sensors, conveyors and fixtures are also needed. Engineers should consider reach and payload when making decisions about how the robot can move around its workspace and interact with everything surrounding it.
ASA’s approach to FANUC robot automation is to use conceptual development and design including CAD Simulation, offline Programming. Digital simulation allows engineers to test configurations and estimate durations of the cycle before the system is operational at the customer’s factory floor. It’s particularly useful when there is a small amount of space or the new robotics has to integrate with a production line.
Painting and dispensing show why Repeatability Matters
Certain manufacturing processes illustrate the importance of controlled movement. Imagine applying a coat to hundreds of parts. The goal isn’t just complete each component at a rapid pace. It’s crucial to regulate the speed, distance, and movement of each component from the beginning until the at the very end.
ASA has specialists working with paint and dispensing processes across various industries, including automotive and aerospace. In these environments industrial robotic automation could allow for repeatable, programmed movements while also reducing employee exposure to physically demanding and potentially dangerous processes.
Better control may also reduce excessive material consumption, thereby contributing to less waste, as well as productivity improvements.
Even after installation it still needs individuals
Automation doesn’t eliminate the requirement for expert manufacturing. Automation alters the knowledge required for maintaining and operating the manufacturing process.
Employees should be able recognize unusual behavior and resolve issues, and carry out the correct maintenance. The processes and procedures can be modified later on if the production needs are changed.
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 ongoing support to evaluate equipment condition and address wear over the system’s operating lifespan.
Capacity is more than Working Faster
In Australia, expanding production capacity doesn’t always mean hiring more workers for repetitive tasks or purchasing bigger buildings. It’s often better to inquire about whether the production process can be improved.
ASA has been working on and integrated automation solutions since 2002, and has been supporting companies in Australia and also projects in other countries. The method is based on the analysis of requirements, engineering, simulations, FANUC robotic integration, training, and also servicing.
Automation for the sake of automation isn’t the main goal. A system worth investing in must provide the manufacturer with measurable results, like greater reliability in production, better quality, safer methods and reduced waste, or an increase in capacity.