A manufacturer gets the contract for a significant amount. The monthly production demands increase, but the factory hasn’t suddenly gained more floor space, experienced employees or even hours per daytime. While adding another shift might temporarily aid, it might also bring new labor as well as training, supervision, and quality-control needs.
These situations reveal a very significant reason to use robotics automation. Robotics isn’t only about replacing humans with machines. When used in the right way it can transform the way producers use the capacity they already have.
Image credit: automatedsolutions.com.au
Take a look at the seconds that disappear between products
Inefficient manufacturing isn’t always obvious. Imagine an operator spending 15 seconds looking for a particular component, 10 seconds applying the material and several seconds transferring it. With a single component it’s a small difference. If repeated thousands of times, these seconds can result in significant production delays.
The same applies to wasted material. A tiny amount of leftover coating or dispensing material multiplied in a production run with a high volume can result in an expense that is significant.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. The needs analysis conducted by ASA is designed to find bottlenecks and waste, quality issues and other process limitations that might affect an automation plan.
Robots must be able to integrate into the process.
The choice of a robotics system is a single decision in engineering. The system will also require tools, guarding control, sensors, conveyors, fixtures, electronic integration, and connectivity with the existing production equipment. Engineers must take into consideration reach and payload when making decisions about how the robot is going to move through its work area and interact with everything around it.
ASA’s approach for FANUC robot automation encompasses the development of concepts and systems including CAD Simulation, offline Programming. Digital simulation lets engineers examine configurations and estimate the cycles before the system can be put in operation on the customer’s factory floor. It’s particularly useful when there is a small amount of space, or when the new robotics needs to integrate with the production line.
Painting and Dispensing demonstrate why the importance of repeatability is evident.
Some manufacturing processes illustrate the importance of controlled motion especially well. Imagine coating hundreds of parts. It’s not enough just to complete each piece in a short time. It’s important to control the speed, distance, and movement of each component from beginning to at the very end.
The experts at ASA are proficient in painting and dispensing across industries such as automotive and aerospace. In these environments industrial robotic automation is able to provide repeatable programmed movement while reducing exposure of employees to physically demanding or dangerous processes.
Improved control can also cut down on unnecessary material consumption, contributing to less waste, as well as productivity gains.
The System Still Needs People After Installation
Automatism isn’t a substitute for manufacturing knowledge. The capabilities needed to manage, maintain, and run the process change.
Employees need to know how to operate equipment in a safe manner identify abnormal behavior as well as troubleshoot issues and perform appropriate maintenance. Production requirements may also alter, which means that procedures and programs might require adjustments later on.
ASA provides training on-site for safe operation, programming, troubleshooting, as well as electrical and mechanical maintenance. The company also provides regular maintenance and services to ensure that the equipment is in good repair and wear and tear issues are taken care of.
Capacity refers to more than the ability to work faster
An increase in capacity for Australian manufacturers doesn’t necessarily need to mean purchasing a larger facility or adding more labor to repeat processes. The better question to ask is whether the existing manufacturing process is able to be improved.
ASA has been working on and integrating automation systems in Australia since 2002. We also provide support for projects in other countries. Its approach combines analysis of needs, engineering, simulations, FANUC robotic integration, training, as well as maintenance.
Automation for the sake of automation isn’t the main goal. A system worth investing in will provide a manufacturer with tangible results, which include better production reliability, higher quality, safer methods and reduced waste, or an increase in capacity.
