A manufacturer wins a major contract. The monthly production demands increase, but the factory isn’t gaining flooring space, skilled workers or even hours per day. A temporary increase in production may be possible, but adding another shift can introduce new labor requirements education, supervision, training and quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics does not only mean replacing humans with machines. It could be utilized to transform the way that manufacturers utilize their existing capacity for production.
Check out the seconds that disappear between the products
Manufacturing inefficiency isn’t always noticeable. Imagine that an operator has spent 15 seconds positioning a component, another 10 seconds applying material, and then a few seconds moving it to the next process. In the case of a single piece, the difference in time is not significant. When repeated thousands of times the second can create significant production time.
This is also true of wasted material. In the event of spreading a small amount extra coating or dispensing materials over a long production run could result in an enormous expense.
Before deciding on the equipment that they need, businesses considering robotic automation Australia can gain from analysing the small loss. ASA’s analysis of requirements is designed to reveal problems with quality and bottlenecks as in addition to the waste that can be a problem during a project.
The robot must fit the process around it
A robot is only one of many engineering options. The system might also require tooling, guarding devices, controls, conveyors, fixtures, electrical integration, and communications with existing production equipment. Engineers must consider the robot’s reach and payload, as well as how it will interact with its environment and how it will move.
ASA offers concepts development, design, CAD simulation and offline programming as part of its strategy to FANUC robotic automation. Digital simulation lets engineers analyze configurations, estimate cycles times and test the system prior to making it operational on the customer’s floor. This is especially helpful when space is limited or if new robotics need to be integrated with the existing lines of production.
The importance of repeatability in painting and dispensing
Controlled movement is crucial for certain manufacturing processes. Imagine coating hundreds of parts. The final result doesn’t come from completing each component quickly. The motion, distance, rate, and even the application needs to be monitored from the beginning of the production process until the time of its completion.
The experts at ASA are proficient in painting and dispensing across different industries including aerospace and automotive. Industrial robotics automation in these areas can allow for repeatable movements as well as limiting the exposure of workers to physically demanding processes or procedures that could risk injury.
A better control of the waste material can also aid in productivity improvement by decreasing the amount of unneeded materials used.
The System Still Needs people after the installation.
Automating doesn’t completely eliminate the requirement for knowledge in manufacturing. The capabilities required to operate, maintain, and control the process evolve.
Employees must be able to recognize abnormal behavior and troubleshoot issues, and perform the appropriate maintenance. Production requirements can change over time, which means that programs and processes will have to be modified.
ASA offers training on-site including programming, safety troubleshooting, and electrical and mechanical maintenance. The company provides servicing and assistance for assessing the condition of equipment, and dealing with wear throughout the lifetime of the system.
Capacity is more than just working faster
In Australia, increasing production capacity does not always mean adding workers to repetitive tasks or buying bigger structures. The better question to ask is whether your current manufacturing process can be improved.
ASA has created and integrated automation systems in Australia since 2002. We also provide support for projects overseas. Its methodology combines analysis of needs as well as engineering, simulations FANUC robotic integration, training, as well as maintenance.
Automation is not for its own sake. A system worth investing in must provide the manufacturer with measurable results, which include more reliable production, higher quality, safer procedures with less waste, or a greater capacity.