A significant contract is won by an industrial manufacturer. While the demands for production have increased, the facility isn’t suddenly equipped with more flooring or experienced workers. An increase in production for a short period is possible, but the addition of a shift could introduce new requirements for labor education, supervision, training and quality control.
These situations reveal a very important reason for robotic automation. Robotics doesn’t just mean replacing humans with the aid of a machine. It can be used to modify the methods that manufacturers employ to use their existing capacity for production.
Image credit: automatedsolutions.com.au
Watch the second-to-second time between the products
Inefficient manufacturing is not always obvious. An operator may spend 15 seconds positioning the component after which 10 seconds are spent applying materials, then a few more seconds moving it onto the next stage. In the case of a single piece, the difference in time is not significant. When repeated a thousand times the second can create significant production time.
Wasted material is no different. A tiny amount of surplus coating or dispensing material that is multiplied throughout a production run that is high-volume can become a meaningful expense.
Before choosing the equipment they require, companies considering robotic automation Australia can benefit by analyzing these tiny losses. The needs analysis of ASA is designed to find bottlenecks, inefficiencies, quality issues, and other constraints to the process that may affect an automation project.
The robot must fit the system around it.
A robot’s selection is only one engineering decision. Guardings, tools, controls as well as conveyors, sensors and fixtures are also required. Engineers must take into consideration reach and payload while also making decisions about how the robot can move around its space and interact with the environment around it.
ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. The digital simulation allows engineers to explore configurations, estimate cycle times and test the system before it is functional on the floor of the customer’s facility. It’s especially useful when there is a small area or new robotics requires integration with a production line.
Painting and dispensing show why Repetability is Important
Some manufacturing processes illustrate the importance of controlled motion especially well. Imagine coating hundreds, or thousands of components. It’s not enough just to finish each part in a short time. From the time of beginning production to the end the speed, movement, distance and application must be controlled.
ASA has specialists working with painting and dispensing applications across industries including automotive and aerospace. In these industries, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or hazardous processes.
Reduced waste and the improvement in productivity is possible through better management.
The System Needs people after the installation.
Automation does not completely eliminate the need for skilled manufacturing. The knowledge needed to operate, maintain, and run the process change.
Employees must be taught to use equipment safely in order to identify any abnormalities or malfunctioning components, and carry out necessary maintenance. Production requirements can change, meaning procedures and programs might require adjustment later.
ASA offers on-site training in programming, safe operation, troubleshooting, and mechanical and electrical maintenance. Additionally, the company provides maintenance and support on a regular basis to assess the condition of the equipment and deal with problems that arise over the system’s operational life.
Capacity is more than working more quickly
The expansion of capacity for Australian manufacturers doesn’t always need to mean purchasing a larger facility or adding more employees to routine processes. Sometimes the better question is whether the existing production process can be redesigned differently.
ASA has been working on and integration of automation systems since 2002, and has been supporting companies in Australia and projects around the world. The method is based on analysis of needs with engineering, simulations FANUC robotic integration and training and also servicing.
Automation is not just for the sake of automation. A system that is effective should provide manufacturers something tangible in the form of more reliable production that is consistent in quality, more secure methods, less waste or more capacity from the existing factory.