A manufacturing company wins a big contract. Even though the production needs for each month have increased, the facility does not have an increase in area for floor or skilled workers. A temporary increase in production could be possible, however adding another shift can bring new requirements for labor as well as training, supervision, and quality control.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. It’s not just about replacing human workers with machines. If it is used correctly, it can change how producers use the capacity they have.
Look at the seconds that disappear between the products
Manufacturing inefficiency doesn’t have to be dramatic. Imagine an operator spending 15 seconds locating a component, 10 seconds applying the material and several seconds to transfer it. On one aspect, the difference seems insignificant. When repeated a thousand times these seconds can create significant production time.
The waste material that is discarded is not different. A small amount of extra coating or dispensing material multiplied across a high-volume production run could be a substantial expense.
Companies looking into robotic automation Australia projects may benefit from studying these tiny regular losses prior to deciding what equipment they need. The needs analysis conducted by ASA is designed to identify bottlenecks as well waste, quality issues and other process constraints which could affect an automation project.
A Robot Must Fit the Process Around It
A robot is just one of many engineering options. It could be necessary to install tooling, protection and controls, sensors conveyors, fixtures, electrical integration, and communication with the existing production equipment. Engineers should consider the payload, reach and range as well as how the robot will be able to move and interact within its environment.
ASA provides the ability to develop concepts, system design and offline programming as part of its approach to robotic automation. Digital simulation lets engineers investigate configurations and estimate cycle times before the completed system is put into operation at the factory floor of the customer’s. This is particularly helpful in situations where space is not available or if new robotics are required to integrate into an existing production line.
Dispensing and painting demonstrate why Replicability is Critical.
Certain manufacturing processes show the importance of controlled movements. Imagine coating hundreds, or thousands of components. It’s not just about completing the components quickly is the desired outcome. It is crucial to manage the speed, distance and movement of each component from the beginning to the final.
The ASA specialists are skilled in dispensing and painting across various industries such as aerospace and automotive. Industrial robotic automation in these environments can allow for repeatable movements and reduce the risk of employees to physically demanding procedures or processes that could be dangerous.
Reduced waste and improvement in productivity could be achieved through better management.
Even after installation, the system still requires people
Automation doesn’t eliminate the requirement for manufacturing knowledge. It transforms the knowledge needed to run and maintain the process.
Employees need to know how to operate equipment in a safe manner identify abnormal behavior as well as troubleshoot issues and conduct the necessary maintenance. Processes and programs can be changed later in the event that production requirements alter.
ASA provides on-site training covering programming, safe operation, troubleshooting, as well as mechanical and electrical maintenance. They also provide servicing and ongoing support to check the condition of equipment and address issues that may arise during the equipment’s operational lifespan.
Capacity is more than working faster
In Australia, boosting production capacity does not always mean hiring more workers for repetitive tasks or purchasing bigger structures. Sometimes, the best question is whether or not the existing production process can be redesigned differently.
ASA has been creating and integrated automation systems since 2002, assisting companies in Australia as well as projects around the world. The approach is a combination of needs analysis, engineering simulation, FANUC integration along with training and servicing.
Automation isn’t the goal. A system worthy of its weight in gold ought to provide measurable benefits to a manufacturer, such as more reliable production, better quality manufacturing processes, and safer ones. It also means less waste.