A manufacturer is awarded a large contract. While the demands for production have risen, the manufacturing facility does not have an increase in floors or more experienced workers. An increase in production for a short period could be possible, however the addition of a shift could introduce new demands for labor education, supervision, training and quality control.
This scenario reveals the primary reason for robots. Robotics isn’t only about replacing human beings with an automated machine. It’s a tool that can transform the way that manufacturers utilize their production capacity.
Image credit: automatedsolutions.com.au
Check out the seconds between products
Inefficiency in manufacturing doesn’t have to be significant. Imagine a worker spending 15 seconds locating a component, 10 seconds applying the material, and then a few seconds to transfer it. It may appear to be a small difference for a single component. It’s a lot when multiplied by thousands.
The waste material that is discarded is not different. Similar is the case for the waste material.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. ASA’s needs analysis is intended to find bottlenecks, inefficiencies, quality issues, and other process constraints which could affect the automation project.
The robot should fit the process around it
The selection of a robot represents only one decision in engineering. The system may also need guarding, tooling devices, controls, conveyors, fixtures, electrical integration, as well as communication with existing production equipment. Engineers should think about the reach, payload and how the robot will operate and interact with its environment.
ASA offers conceptual development, design of systems and offline programming as part of its method of robotic automation. Digital simulation allows engineers to examine configurations and estimate the time-to-market before the system is put into operation on the customer’s factory floor. It’s especially useful when there is a limited amount of space, or when the new robotics is required to be integrated with a production line.
Painting and Dispensing demonstrate why Repetability is Important
Controlled movement is crucial for certain manufacturing processes. Imagine covering hundreds of components. It’s not enough just to finish each component quickly. It’s important to control the speed, distance and movement of each piece from the beginning to the final.
ASA has specialists who work on painting and dispensing systems across a variety of industries, including automotive and aerospace. In these environments industrial robotic automation can provide repeatable, programmed movements and reduces employee exposure to physically challenging or potentially dangerous processes.
Better control of waste material can also increase productivity by reducing the amount of unnecessary material consumed.
Installation of the system isn’t enough. It is still necessary to have people to maintain it.
Automatism doesn’t replace manufacturing knowledge. It changes the skills required to manage and maintain the process.
Employees must be instructed to safely use equipment as well as to spot abnormal behavior and troubleshoot malfunctioning components and complete any necessary maintenance. The production needs can change in time, meaning that procedures and protocols will need to be adjusted.
ASA provides on-site training covering safe operation, programming, troubleshooting, and electrical and mechanical maintenance. The company provides ongoing maintenance and repairs to ensure that equipment is in top repair and wear and tear issues are dealt with.
Capacity is about more than just getting faster work done
For Australian manufacturers, increasing capacity doesn’t necessarily mean purchasing a larger building or continually increasing the amount of labor required to perform repetitive tasks. Sometimes, it is better to inquire if the manufacturing process could be redesigned.
ASA has been working on and integrating automation solutions in Australia since 2002. We also assist with projects abroad. Its approach combines needs analysis along with engineering simulation FANUC integration along with training and servicing.
Automating for automation’s sake isn’t the objective. Any system that is worth investing in must provide the manufacturer with measurable results, which include increased reliability of production, improved quality, safer procedures, reduced waste or increased capacity.