A major contract is won by an industrial manufacturer. Monthly production requirements increase, yet the factory does not suddenly gain flooring space, skilled workers or working hours during the day. A second shift may help temporarily, but it can also introduce new labor, 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 replace humans with machines. A good application could change the way manufacturers utilize their production capacity.
Check out the seconds between the products
Inefficiency in manufacturing doesn’t need to be dramatic. An operator may spend 15 seconds assembling the component, then 10 seconds applying substances, and then a few seconds to move it onto the next stage. On one aspect the difference isn’t that significant. If repeated thousands of times however the second can add significant production time.
The same applies to wasted material. The addition of a tiny amount of additional coatings or dispensing material over a long production line can lead to a significant expense.
The companies that are considering robotic automation Australia will benefit by analyzing these tiny loss, repeated ones before they decide on the best equipment to buy. AAS’s Needs Analysis aims to uncover bottlenecks as well problems with quality, waste and other process constraints which can affect the automation project.
The robot should fit the system around it.
A robot is only one of many engineering options. It could be necessary to incorporate tooling, security and controls sensors, conveyers, fixtures, electrical integration, and communication to the production equipment already in place. Engineers must consider reach and payload when determining how the robot can move around its workspace and interact with the environment surrounding it.
ASA offers conceptual development, system design, CAD simulation, and offline programming as an element of its approach to FANUC’s robotic automation. Engineers can investigate system configurations and estimate cycle times before the finished system is installed on the factory floor. It is particularly helpful when there is a limited amount of space, or when the new robotics is required to be integrated with an existing production line.
Painting and Dispensing demonstrate why the importance of repeatability is evident.
Certain manufacturing processes show the importance of controlled movement. Imagine coating hundreds of components. The final result doesn’t come from completing each component quickly. It’s crucial to regulate the speed, distance, and movement of each part from the beginning to the final.
The ASA specialists are skilled in dispensing and painting across various industries like aerospace and automotive. In these areas, industrial robotic automation allows for regular, programmatic movements and reduces employee exposure to physically challenging or potentially hazardous processes.
A better control system can also help reduce the amount of material used, which can lead to less waste, as well as productivity improvement.
Even after the installation it still needs users
Automation doesn’t substitute for manufacturing expertise. Automation changes the skills needed for maintaining and operating the manufacturing process.
Employees must be able to detect abnormal behavior and identify problems, as well as do the proper maintenance. The processes and procedures can be adjusted later if the production needs alter.
ASA provides training on site in safe operation, programming and troubleshooting as well as electrical and mechanical maintenance. The company provides servicing and support to check equipment condition, and addressing wear throughout the lifetime of the system.
Capacity is about more than the ability to work faster
An increase in capacity for Australian manufacturers does not necessarily mean buying a bigger building or adding more labor to repetitive processes. Sometimes the better question is whether the existing manufacturing process could be designed differently.
ASA has been working on and integration of automation solutions since 2002. It has assisted companies in Australia and projects across the globe. Its method of analysis connects needs and engineering with simulation FANUC robot integration Training, and servicing.
Automation is not the aim. A worthwhile system should give manufacturers something tangible in yield, more stable production with consistent quality, safe processes, lower waste or a larger capacity for the facility it operates.