A major contract is won by an industrial manufacturer. Although the monthly production requirements have increased, the factory isn’t suddenly equipped with more flooring or experienced workers. A temporary increase in production may be possible, but adding another shift can introduce new demands for labor, training, supervision and quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics does not only mean replacing human workers with machines. The right application can transform how manufacturers use their capacity to produce.
Take a look at the amount of time that is lost between products
Inefficient manufacturing may not be obvious. Suppose an operator spends 15 minutes putting a piece of equipment in place, another 10 seconds applying material, and then a few minutes transferring it to the next step. For one part the difference isn’t that significant. If repeated thousands of times, however, those seconds become significant production time.
Wasted material is no different. A small amount of additional coating or dispensing materials throughout a massive production run can result in substantial costs.
Companies looking into robotic automation Australia projects can benefit from studying these tiny 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 constraints which can affect the automation project.
A Robot must be able to integrate the Process Itself
Making a choice on a robot is only one decision in engineering. It could be necessary to incorporate tooling, security and controls, sensors conveyors, fixtures, electronic integration, and communications with existing production equipment. Engineers must take into consideration the robot’s reach and payload, in addition to how it will interact with its surroundings and how it will move.
ASA’s approach for FANUC robot automation is based on concept development, system design, CAD Simulation, and offline programming. Digital simulation lets engineers explore configurations, estimate cycle times, and evaluate the system prior to making it in operation on the floor of the customer’s. That becomes particularly useful when space is constrained or if new robotics are required to integrate into an existing production line.
Paint and Dispensing demonstrates why Replicability is Crucial
Certain manufacturing processes show the importance of controlled motion particularly well. Imagine covering hundreds of components. It’s not just about completing the components quickly is the desired outcome. It’s important to control the speed, distance and the movement of every component from the beginning to the very end.
ASA is a specialist in painting and dispensing systems across a variety of industries, including automotive and aerospace. In these areas industrial robotic automation may allow for repeatable, programmed movements and reduce exposure of employees to physically demanding or hazardous processes.
Improved control can also cut down on the amount of material used, which can lead to less waste, as well as productivity enhancements.
Installing the system is not enough. It is still necessary to have people to manage it.
Automation does not eliminate the requirement for expert manufacturing. Automation transforms the skills required for maintaining and operating the manufacturing process.
Employees must be taught to use equipment safely and to recognize abnormal behavior and troubleshoot malfunctioning components and complete any necessary maintenance. Processes and programs can be adjusted later if production requirements shift.
ASA offers training on site that covers safe operation, programming, troubleshooting, and mechanical and electrical maintenance. The company provides ongoing maintenance and servicing to ensure that equipment is in good order and wear and tear issues are dealt with.
Capacity goes beyond just getting faster work done
An increase in capacity for Australian manufacturers doesn’t necessarily mean buying a bigger building or adding more labor to repetitive processes. It’s sometimes more beneficial to inquire if the manufacturing process could be redesigned.
ASA has been developing and integrated automation solutions since 2002. It assists manufacturers in Australia and international projects. The approach is a combination of needs analysis as well as engineering simulation. FANUC integration as well as training and maintenance.
Automation for the sake of automation isn’t the main goal. A system that is effective should provide the manufacturer something tangible in the form of more reliable production and quality, as well as safer processes, lower waste or additional capacity from the facility it operates.