A manufacturer is awarded a large contract. Monthly production requirements increase, but the factory hasn’t suddenly gained more floor space, experienced employees or working hours during the day. While adding another shift may temporarily help, it could be the cause of additional labor or supervision, as well as additional training and the need for quality control.
Image credit: automatedsolutions.com.au
Such situations highlight the purpose behind robotic automation. It’s not just about replacing human beings with machines. It is able to alter the method by which manufacturers use their current production capacity.
You can check out the time difference between the products
Manufacturing inefficiency isn’t always significant. Imagine a worker spending 15 seconds looking for a particular component and then 10 seconds putting it into the material and several seconds transferring it. On a single part, the difference in time is not significant. Those seconds add up when multiplied by thousands.
Material that has been wasted isn’t different. A small amount of extra coating or dispensing substances across a large production run could lead to a significant expense.
The companies that are considering robotic automation Australia will gain from analyzing these small loss, repeated ones before they decide on the best equipment to buy. ASA’s needs analysis is designed to pinpoint bottlenecks, inefficiencies, quality issues, and other constraints to the process which could affect the automation project.
A Robot must be able to integrate the Process Itself
A robot is just one of many engineering decisions. The system may also need tooling, guarding and controls, sensors conveyors, fixtures electrical integration, as well as communication with the existing production equipment. Engineers must take into consideration the robot’s reach and payload as well as how it interacts with its environment and move about.
ASA’s approach for FANUC robot automation is to use concept development and system design as well as CAD Simulation and offline Programming. Digital simulation allows engineers to examine configurations and estimate the cycle times before the completed system can be put in operation on the customer’s factory floor. It is particularly helpful when there is a small amount of space or the new robotics has to integrate with an existing production line.
The importance of repeatability when painting and dispensing
Certain manufacturing processes show the benefits of controlled movement especially well. Imagine applying a coating to hundreds of components. It’s not enough just to complete each piece quickly. From the beginning of production until the final stage moving, speed and distance must be controlled.
ASA has experts who deal in the field of dispensing and painting across all industries, including aeronautics and automotive. In these environments, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially hazardous processes.
An improved control over waste material can also increase productivity by cutting down on the amount of waste material consumed.
The System Will Still Need People Even After Installation
Automation does not eliminate the requirement for manufacturing knowledge. The knowledge required to manage, maintain and operate the process shift.
Employees need to know how to operate equipment in a safe manner identify abnormal behavior or malfunctions, then troubleshoot the issue and take care of maintenance. Systems and procedures can be changed later in the event that the production needs alter.
ASA offers on-site training covering safety, programming troubleshooting, and electrical and mechanical maintenance. The company offers servicing and support for checking the condition of equipment, and dealing with wear and tear throughout the life of the system.
Capacity goes beyond simply working faster
For Australian manufacturers, increasing capacity doesn’t necessarily mean purchasing an additional building or adding more workers to repetitive processes. Sometimes, the most important thing to consider is whether the existing production process can be engineered differently.
ASA has been creating and the integration of automation solutions since 2002. It works with the manufacturing industry in Australia and international projects. The approach is a combination of needs analysis and engineering simulation with FANUC integration along with training and servicing.
The objective isn’t automation for its own sake. An investment in a system should provide a company with quantifiable results, including better production reliability, higher quality, safer processes, reduced waste or increased capacity.