A large contract is signed by the manufacturer. Production requirements for the month are increased, but the manufacturing facility hasn’t suddenly gained more flooring space, skilled workers or hours of work per day. While adding another shift might temporarily boost production, it could also bring new labor in the form of supervision, training, or the need for quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics goes beyond replacing people with machines. It can be used to change the way manufacturers utilize their existing capacity for production.
Look at the Seconds That Change Between Products
Manufacturing inefficiency doesn’t have to be dramatic. A worker may take 15 minutes positioning the item, then 10 seconds applying materials, and then a few seconds more to move it onto the next stage. It may appear to be a small difference for a single part. It’s a lot when multiplied by thousands.
Wasted material is no different. Similar is the case for waste material.
Companies that are thinking about robotic automation Australia can benefit from studying these small, repetitive losses before they decide which equipment to buy. The analysis of needs by ASA aims to uncover bottlenecks as well the quality of work, waste and other limitations to process that might affect an automation plan.
The robot should fit the process around it
Selecting a robot is only one decision in engineering. The system may also need tooling, guarding control, sensors conveyors, fixtures electrical integration, and communications with the existing production equipment. Engineers need to consider the reach and payload of the robot while making decisions about how the robot will move through its workspace and interact with the environment around it.
The FANUC approach of ASA’s approach to robot automation is based on conceptual development and design along with CAD Simulation and offline programming. Engineers can explore system configurations and estimate cycle times before the final system is put in the factory floor. It’s particularly useful in situations where there is a restricted amount of space, or when the new robotics requires integration with the production line.
Painting and dispensing show why It’s Important to Repeat
Controlled movement is especially important in certain manufacturing processes. Imagine coating hundreds or thousands of parts. The ability to finish components in a short time is the goal. The movement, distance, speed, and the application must to remain controlled from the beginning of the production process to the time of its completion.
ASA has specialists who work in the field of dispensing and painting across various industries, such as automotive and aeronautics. In these areas, industrial robotic automation can offer repeatable programming while also reducing employee exposure to physically demanding or potentially dangerous processes.
The reduction in waste and the increase in productivity could be achieved through better management.
Installing the system is not enough. It is still necessary to have people to keep it running.
Automatism isn’t a substitute for manufacturing knowledge. Automation transforms the skills required to operate and maintain the manufacturing process.
Employees must be taught to operate equipment in a safe manner as well as to spot abnormal behavior, troubleshoot faulty components, and perform necessary maintenance. Production requirements may also be changed, which means processes and programs may require adjustments later on.
ASA offers on-site training in safe operation, programming troubleshooting, as well as mechanical and electrical maintenance. The company also provides maintenance and support for checking the condition of equipment and taking care to address wear throughout the lifespan of the equipment.
Capacity is greater than working more quickly
The expansion of capacity for Australian manufacturers doesn’t always require the purchase of a larger building or adding more labor to repeat processes. Sometimes the better question is whether the existing manufacturing process can be designed differently.
ASA has been working on and the integration of automation systems since 2002, supporting companies in Australia as well as projects around the world. The company’s strategy combines analysis of needs and engineering with simulation FANUC robot integration training, as well as servicing.
Automating for automation’s sake isn’t a goal. A worthwhile system should give a manufacturer something measurable in the form of more reliable production with consistent quality, safe procedures, less waste or more capacity from the factory it already operates.