A manufacturing company wins a big contract. Even though the production needs for each month have increased, the facility does not suddenly have more floors or more experienced workers. An increase in production for a short period might be possible, but an additional shift may bring new requirements for labor as well as training, supervision, and quality control.
Image credit: automatedsolutions.com.au
These circumstances reveal an important motive for the use of robotic automation. Robotics is not just replacing humans with machines. It’s a tool that can alter the method by which manufacturers use their current production capacity.
Look at the Seconds That disappear between products
Inefficiency in manufacturing doesn’t have to be a major issue. If an operator takes 15 seconds arranging a part for 10 seconds, then another 10 seconds applying material, and several more minutes transferring it to the next step. On a single part, the difference is minimal. It’s a lot when multiplied by thousands.
Material that has been wasted isn’t different. The addition of a tiny amount of additional coatings or dispensing material in a huge production run could lead to the cost of a large amount.
Companies looking into robot automation Australia projects will gain from examining these minor regular losses prior to making a decision on the equipment they require. ASA’s needs analysis is intended to identify bottlenecks, inefficiencies, quality issues, and other processes that could influence an automation project.
A Robot has to fit the Process Around It
The selection of a robot is a single decision in engineering. Controls, guardings and tooling sensors, conveyors and fixtures may also be needed. Engineers should think about the reach, payload and how the robot is going to be able to move and interact within the surrounding.
ASA provides concept development, system design and offline programming in its method of robotic automation. Digital simulation allows engineers to test configurations and estimate time-to-market before the system can be put in operation at the factory floor of the customer’s. This is especially useful when space is constrained or when new robotics need to be integrated with a production line that is already in place.
It is crucial to have repeatability in painting and dispensing
Controlled movement is especially important for certain manufacturing processes. Imagine applying a coating on hundreds of parts. It’s not enough to finish each component quickly. From the moment of starting production to the end moving, speed of the machine, the distance and the application have to be managed.
ASA is a specialist in painting and dispensing applications across a range of industries including automotive as well as aerospace. In these environments, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially hazardous processes.
The reduction of waste and the increase of productivity can be accomplished through better control.
The installation of the system isn’t enough. It is still necessary to have people to maintain it.
Automating doesn’t completely eliminate the need for manufacturing expertise. Automation alters the knowledge required to operate and maintain the process.
Employees should be trained to safely use equipment as well as to spot abnormal behavior, troubleshoot faulty components, and perform necessary maintenance. The production requirements can also be changed, which means the processes and programs could require modification later.
ASA offers training on-site in safe operation, programming and troubleshooting, in addition to mechanical and electrical maintenance. The company offers ongoing maintenance and service to ensure that equipment is in top repair and wear and tear issues are dealt with.
Capacity refers to more than working faster
A rise in capacity for Australian manufacturing companies doesn’t require the purchase of a larger building or adding more labor on repetitive processes. Sometimes, the most important thing to consider is whether the present manufacturing process could be designed differently.
ASA has been working on and integrating automation solutions since 2002, and has been supporting manufacturers in Australia as well as projects internationally. Its method combines analysis of needs, engineering, simulations, FANUC robotic integration training, as well as servicing.
Automating just for the sake of it isn’t the goal. A worthwhile system should give the manufacturer something tangible in yield, more stable production, consistent quality, safer procedures, less waste or more capacity from the facility it operates.