A manufacturer is awarded a large contract. The monthly production needs increase however the facility isn’t equipped with more space or employees who have experience or more hours to work during the daytime. While adding a second shift could temporarily aid, it might also create new jobs in the form of supervision, training, or requirements for quality control.
This kind of situation reveals an important purpose of robotic automation. Robotics isn’t only about replacing people with machines. It’s a tool that can alter the method by which manufacturers use their existing capacity for production.
Image credit: automatedsolutions.com.au
Take a look at the time that passes between products
Inefficient manufacturing may not be apparent. An operator may spend 15 minutes positioning the item, then 10 seconds applying materials, and a few seconds more to move it to the next step. With a single component the difference in time is not significant. Those seconds add up when multiplied by thousands.
It is the same with scrap material. The same is true of waste materials.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. AAS’s Needs Analysis aims to pinpoint bottlenecks, as well waste, quality issues and other limitations to process that might affect an automation plan.
Robots need to be able be integrated into the process.
A robot’s selection is only one engineering decision. The system might also require guarding, tooling control, sensors, conveyors, fixtures, electrical integration, as well as communication with existing production equipment. Engineers must consider the reach, payload and how the robot is going to be able to move and interact within the surrounding.
ASA provides conceptual development, system design, CAD simulation, and offline programming as an element of its approach to FANUC’s robotic automation. Engineers can investigate system configurations and calculate cycles prior to when the final system is put on the factory floor. That becomes particularly useful when space is constrained or when new robotics have to integrate into an existing production line.
Painting and Dispensing Show Why Repetability is Important
Certain manufacturing processes highlight the importance of controlling movements. Imagine coating hundreds, or thousands of components. It’s not enough just to finish each component quickly. From the time of beginning production until the final stage moving, speed as well as the distance to be applied must be managed.
ASA has specialists who work on paint and dispensing processes across various industries, including automotive and aerospace. In these environments industrial robotic automation offers repeatable, programmed movements and reduces exposure of employees to physically challenging or potentially hazardous processes.
A better control system can also help reduce the amount of material used, which can lead to a decrease in waste as well as productivity improvements.
Even after the installation the system will still require users
Automation does not eliminate the need for skilled manufacturing. It alters the knowledge required for operating and maintaining the process.
Employees must be taught to use equipment safely, identify abnormal behavior, troubleshoot faulty components, and take care of any maintenance that is required. Processes and programs can be adjusted later if production requirements are changed.
ASA provides training on site in safe operation, programming and troubleshooting. It also offers maintenance for electrical and mechanical components. Additionally, the company provides maintenance as well as ongoing support to evaluate the condition of the equipment and deal with problems that arise over the system’s operational life.
Capacity is more than Being able to work faster
For Australian manufacturers, increasing capacity doesn’t necessarily mean buying larger buildings or adding labor to repetitive processes. Sometimes, it is better to inquire about whether the production process can be improved.
ASA has been designing and the integration of automation solutions since 2002. It works with companies in Australia, as well as international projects. Its methodology combines the analysis of requirements, engineering, simulations, FANUC robotic integration, training, as well as servicing.
Automation is not the only goal. A system that’s worth its weight in gold must be able to provide tangible benefits for the manufacturer, like higher reliability in production, improved quality, safer processes and less waste.