A manufacturing company wins a big contract. Monthly production requirements are increased, but the manufacturing facility does not suddenly gain area for floor, skilled employees or working hours during the day. It is possible to add another shift in the short term, but it could create new labor as well as training, supervision and quality control requirements.
Situations like this reveal an important purpose of robotic automation. Robotics isn’t only about replacing human beings with machines. If used properly, it can change how companies use the capacity they already have.
Image credit: automatedsolutions.com.au
Look at the time that passes between the products
Inefficient manufacturing isn’t always apparent. If an operator takes 15 seconds arranging a part and then 10 seconds putting it in the material, and a few seconds transferring it to the next operation. On one piece, the difference seems insignificant. When repeated thousands of times however, those seconds become an enormous amount of production time.
It’s the same for waste materials. The addition of a tiny amount of extra coating or dispensing substances across a large production run can result in a significant expense.
Companies that are thinking about robotic automation Australia could benefit from analyzing these small, repetitive losses before they decide on the best equipment to buy. The analysis provided by ASA is designed to pinpoint problems with quality and bottlenecks, as well as any other limitations in a project.
Robots should be able to work with the system.
The choice of a robot is just one engineering decision. It might be necessary to incorporate tooling, security and controls, sensors as well as conveyers, fixtures electrical integration, and communication with the existing production equipment. Engineers need to consider the payload and reach while making decisions about how the robot will move about its work area and interact with everything surrounding it.
ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. Engineers can investigate system configurations and calculate cycles prior to when the system is finally installed in the factory floor. This is particularly beneficial when space is constrained or new robotics must integrate with a production line that is already in place.
The importance of consistency in painting and dispensing
Controlled movement is essential in certain manufacturing processes. Imagine applying a coating on hundreds of parts. Not just completing components quickly is what you want to achieve. The movement, distance, speed, and application need be managed at the beginning of the production process until the point of completion.
ASA has experts who deal on dispensing and paint applications across all industries, including automotive and aeronautics. In these areas industrial robotic automation could offer repeatable programming and reduce exposure of employees to physically demanding and potentially hazardous processes.
A better control of the waste material can also increase productivity by reducing the amount of unnecessary material consumed.
Even after the installation the system will still require users
Automating doesn’t completely eliminate the requirement for knowledge in manufacturing. The skills needed to manage, maintain and run the process change.
Employees must be instructed to use equipment safely and to recognize abnormal behavior as well as troubleshoot components that are malfunctioning and perform necessary maintenance. Programs and processes can be modified later on if the production needs change.
ASA provides training on site in safe operation, programming, troubleshooting. It also offers maintenance of electrical and mechanical systems. The company offers ongoing maintenance and servicing to ensure that the equipment is in top working order and wear and tear issues are taken care of.
Capacity goes beyond just getting faster work done
An increase in capacity for Australian manufacturers doesn’t necessarily mean buying a bigger building or adding additional labor to repetitive processes. Sometimes, the more important question is whether the current manufacturing process could be designed differently.
ASA has developed and integrated automation solutions in Australia since 2002. We also help with projects across the world. Its strategy combines analysis of needs along with engineering simulation FANUC integration, training and servicing.
Automation is not the aim. A system worth investing in should offer a manufacturer measurable results, including increased reliability of production, improved quality, safer methods and reduced waste, or an increase in capacity.
