A significant contract is won by an industrial manufacturer. While the demands for production have increased, the factory does not have an increase in floor space or experienced employees. Adding another shift might help in the short term, but it could create new labor and training, supervision, and quality-control demands.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics doesn’t just mean replacing humans with machines. In the right application it could alter the way companies use the capacity they already have.
Examine the Seconds That Change Between Products
Inefficiency in manufacturing isn’t always so evident. A worker could spend 15 minutes putting the part in place before implementing 10 seconds of materials, then a few seconds more to move it to the next step. The time difference could seem minor for a single part. If repeated thousands of times the seconds could add significant production time.
It’s the same for waste materials. This is also true for the waste material.
Before deciding on the equipment that they require, businesses looking into robotic automation Australia will benefit from studying these tiny losses. The needs analysis conducted by ASA is designed to pinpoint bottlenecks, as well waste, quality issues and other process constraints which could affect an automation project.
Robots should be able to integrate into the process.
A robot’s selection is only one engineering decision. It might be necessary to include tooling, guarding and controls sensors, conveyers, fixtures, electrical integration, and communication with the existing production equipment. Engineers should take into consideration reach, payload and how the robot will be able to move and interact within the environment.
ASA offers the ability to develop concepts, system design and offline programming as part of its approach to robotic automation. Engineers can investigate system configurations and estimate the number of cycles required before the final system is put in the factory floor. It’s especially useful when there is a limited amount of space or the new robotics needs to integrate with an existing production line.
The importance of repeatability in painting and dispensing
Some manufacturing processes illustrate the benefits of controlled movement particularly well. Imagine covering hundreds of components. The final result doesn’t come from the process of completing every component in a short time. From the start of production until the final stage the speed, movement and distance must be controlled.
ASA is a specialist in painting and dispensing systems across a variety of industries, including automotive and aerospace. In these settings, industrial robotic automation provides predictable, controlled movements. It also decreases the risk of exposure for employees to physically challenging or potentially hazardous processes.
A better management of waste materials can also contribute to productivity improvements by reducing the amount of unnecessary materials used.
The System Needs People Even After Installation
Automation can’t replace the manufacturing know-how. Automation alters the knowledge required to maintain and operate the process.
Employees must be able to spot abnormal behavior and solve problems, as well as do the proper maintenance. Production requirements can also alter, which means that the processes and programs could require adjustments later on.
ASA offers training on site covering safety, programming troubleshooting, and mechanical and electrical maintenance. The company offers servicing as well as support for evaluating the condition of equipment, and dealing with wear and tear throughout the life of the system.
Capacity is greater than working faster
An increase in capacity for Australian manufacturers doesn’t necessarily require the purchase of a larger building or adding more labor to repetitive processes. It’s often better to inquire about whether the production process can be modified.
ASA has been developing and integrating automation solutions since 2002, and has been supporting companies in Australia and also projects around the world. The company’s strategy combines analysis of needs with engineering, simulation, FANUC robot integration, training, and servicing.
Automation isn’t a goal. Any system that is worth investing in must provide the manufacturer with measurable results, like increased reliability of production, improved quality, safer methods as well as reduced waste or a higher capacity.