A company is awarded a large contract. While the demands for production have increased, the facility isn’t suddenly equipped with more floor space or experienced employees. Although adding another shift may temporarily help, it could be the cause of additional labor in the form of supervision, training, or requirements for quality control.
This scenario reveals the primary need for robotic automation. Robotics goes beyond replacing people with machines. It could be utilized to alter the method by which manufacturers use their existing production capacity.
Image credit: automatedsolutions.com.au
Take a look at the seconds that Change Between Products
Inefficiency in manufacturing isn’t always so dramatic. If an operator takes 15 seconds arranging a part for 10 seconds, then another 10 seconds applying materials, and then several seconds to transfer it onto the next task. In the case of a single piece, the difference in time is not significant. If repeated thousands of times, but those seconds turn into significant production time.
The same applies to wasted material. A tiny amount of leftover coating or dispensing material that is multiplied throughout a production run that is high-volume could result in a significant expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. The analysis of needs by ASA aims to pinpoint bottlenecks, as well problems with quality, waste and other process limitations that can affect the automation project.
The robot needs to be able to accommodate the procedure around it.
A robot’s selection is only one of the engineering decisions. It could be necessary to install tooling, protection and controls sensors conveyors, fixtures, electrical integration, and communication with the current production equipment. Engineers should consider reach and payload when determining how the robot will move about its work area and interact with the environment surrounding it.
ASA’s approach for FANUC robot automation is to use the development of concepts and systems including CAD Simulation, offline Programming. Digital simulation allows engineers to explore configurations and estimate cycles before the system is operating in the factory of the customer’s. That becomes particularly useful when space is limited or when new robotics have to integrate into an existing production line.
Painting and Dispensing demonstrates why the importance of repeatability is evident.
The ability to control movement is particularly important in some manufacturing processes. Imagine coating hundreds of components. The goal isn’t just complete each component at a rapid pace. It’s crucial to regulate the speed, distance and movement of each component from beginning to final.
ASA has specialists who work in the field of dispensing and painting across various industries, including aeronautics and automotive. Industrial robotic automation in these environments allows for reproducible movements while reducing the exposure of workers to physically demanding processes or ones that may be hazardous.
Reduced waste and the improvement in productivity could be achieved through better control.
Installing the system is not enough. You will require people to manage it.
Automating doesn’t completely eliminate the requirement for manufacturing knowledge. Automation can alter the capabilities needed to operate and maintain the process.
Employees must be taught to operate equipment in a safe manner, identify abnormal behavior or malfunctioning components, and take care of any maintenance that is required. Production requirements can change in time, meaning that the processes and programs require adjusting.
ASA provides training on-site for safe operation, programming troubleshooting, and mechanical and electrical maintenance. The company offers ongoing maintenance and servicing to ensure that the equipment is in good working order and wear and tear issues are taken care of.
Capacity is more than just working more quickly
For Australian producers, expanding capacity doesn’t necessarily mean buying an additional building or adding labor to repetitive processes. Sometimes, the most important thing to consider is whether the existing manufacturing process can be designed differently.
ASA has been creating and integration of automation systems since 2002, supporting companies in Australia as well as projects internationally. The approach combines needs analysis, engineering, simulation, FANUC robot integration, training, and servicing.
Automation for the sake of automation isn’t the main goal. An investment in a system must provide the manufacturer with measurable results, which include better production reliability, higher quality, more secure procedures as well as reduced waste or a higher capacity.