A significant contract is won by the manufacturer. Monthly production requirements are increased, but the manufacturing facility hasn’t seen a sudden increase in floors, employees with experience or even hours per daytime. It is possible to add another shift temporarily, but it may also create new work as well as training, supervision and quality-control requirements.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. It’s not just about replacing humans with machines. The right application can transform how manufacturers use their production capacity.
Check out the seconds between products
Manufacturing inefficiency doesn’t have to be a major issue. A worker may take 15 seconds positioning the component and then 10 seconds putting on materials, and a few more seconds moving it onto the next stage. With a single component the difference is insignificant. If repeated thousands of times, however, those seconds become significant production time.
It’s the same with waste material. A tiny amount of surplus coating or dispensing material that is multiplied in a production run with a high volume can become a meaningful expense.
Before making a decision on the equipment they need, businesses considering robotic automation Australia can benefit by analyzing the small loss. ASA’s needs analysis aims to uncover bottlenecks as well waste, quality issues and other process constraints which could affect an automation project.
Robots have to integrate into the process.
The decision to choose a robot represents only one decision in engineering. The system will also require tooling, guarding and controls, sensors, conveyors, fixtures, electrical integration, as well as communication with existing production equipment. Engineers must consider the robot’s reach and payload, as well as how it interact with its surroundings and how it will move.
ASA’s approach to FANUC robot automation includes conceptual development and design including CAD Simulation, offline Programming. Engineers can look at system configurations and estimate cycles before the system is finally installed on the floor of the factory. This is particularly helpful in situations where space is not available or if new robotics are required to integrate with an established production line.
Paint and Dispensing Shows Why Replicability is Critical.
Controlled movement is crucial in certain manufacturing processes. Imagine covering a variety of components. The goal isn’t just the process of completing every component in a short time. It’s important to control the speed, distance and movement of each component from beginning to very end.
ASA is a specialist in painting and dispensing solutions across a range of industries including automotive as well as aerospace. Industrial robotic automation in these environments will allow for repeatable movement as well as limiting the exposure of employees to physical demanding processes or procedures that could be dangerous.
Improved control can also cut down on unnecessary material consumption, contributing to a decrease in waste as well as productivity improvement.
Even after installation, the system still requires individuals
Automation can’t replace the manufacturing know-how. The knowledge required to operate, maintain, and manage the process are changing.
Employees must be taught to operate equipment in a safe manner and to recognize abnormal behavior and troubleshoot malfunctioning components and perform necessary maintenance. Production requirements can also be changed, which means procedures and programs might require modification later.
ASA provides training on site in safe operation, programming, troubleshooting, as well as maintenance for electrical and mechanical components. The company also provides servicing and ongoing support to check the condition of equipment and to address wear over the system’s operating life.
Capacity Is About More Than Being able to work faster
In Australia, increasing production capacity doesn’t always mean hiring more workers for repetitive tasks or purchasing larger structures. Sometimes, the best question is whether the existing manufacturing process could be designed differently.
ASA has been creating and the integration of automation solutions since 2002. It has assisted manufacturers in Australia and projects in other countries. The approach is a combination of needs analysis as well as engineering simulation. FANUC integration training, and service.
The goal isn’t to automate just for the sake of automation. A system that is worth its weight in gold should be able to provide tangible benefits for the manufacturer, like higher reliability in production, improved quality, safer processes and less waste.