A manufacturer is awarded a large contract. While the demands for production have increased, the factory doesn’t suddenly have more flooring or experienced workers. An increase in production for a short period could be possible, however adding another shift can introduce new requirements for labor, training, supervision and quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics doesn’t just mean replacing people with a machine. It is able to alter the method by which manufacturers use their current production capacity.
Look at the Seconds That Change Between Products
Manufacturing inefficiency doesn’t have to be dramatic. A worker may take 15 minutes positioning the item after which 10 seconds are spent applying materials, and a few more seconds moving it onto the next stage. With a single component the difference is minimal. It’s a lot when multiplied by thousands.
It’s the same for waste material. A small amount of extra coating or dispensing material multiplied throughout a production run that is high-volume could result in a significant expense.
Before choosing the equipment they will require, companies looking at robotic automation Australia will benefit from studying the tiny losses. The analysis of needs by ASA aims to pinpoint bottlenecks, as well waste, quality issues and other process limitations that could impact an automation project.
The robot must fit the system around it.
The decision to choose a robot is only one of the decisions in engineering. Tools, guardings, controls sensors, conveyors and fixtures are also necessary. Engineers should consider reach, payload and how the robot is going to move and interact in the environment.
The ASA approach to FANUC robot automation is to use concept development and system design as well as CAD Simulation and offline programming. The digital simulation allows engineers to explore configurations, estimate cycle time and allow them to test the system prior to it becoming functional on the floor of the customer’s facility. This is particularly helpful when space is limited or if new robotics require to be integrated into the existing lines of production.
The importance of consistency in painting and dispensing
Controlled movement is crucial for certain manufacturing processes. Imagine applying a protective coating to hundreds of parts. Making components faster is the ideal outcome. From the time of beginning production to the end, the movement, speed, distance and application must be controlled.
Our specialists have experience painting and dispensing across different industries including aerospace and automotive. In these industries industrial robotic automation is able to offer repeatable programming while also reducing employee exposure to physically demanding or potentially dangerous processes.
The reduction of waste and the improvement in productivity could be achieved by better control.
Even after installation the system will still require users
Automation doesn’t eliminate the requirement for manufacturing knowledge. It changes the skills required to run and maintain the process.
Employees should be aware of how to operate equipment safely be aware of abnormal behavior as well as troubleshoot issues and perform appropriate maintenance. Programs and processes are able to be changed later if the production needs shift.
ASA provides training on site in safe operation, programming, troubleshooting, as well as mechanical and electrical maintenance. They also provide servicing and support for checking the condition of equipment, and dealing with wear and tear throughout the life of the system.
Capacity is greater than working faster
The expansion of capacity for Australian manufacturing companies doesn’t require the purchase of a larger building or adding additional labor to routine processes. Sometimes, the most important thing to consider is whether the existing production process can be engineered differently.
ASA has been working on and integrating automation solutions in Australia since 2002. We also help with projects abroad. Its strategy combines analysis of needs and engineering simulation with FANUC integration along with training and servicing.
Automation is not for its own sake. A good system will give a manufacturer something measurable in terms of increased reliability and quality, as well as safer processes, less waste, or a greater capacity in the factory that it currently operates.