A manufacturing company gets an enormous contract. While the requirements for monthly production have increased, the facility does not suddenly have more floors or more experienced workers. A temporary increase in production is possible, but adding another shift can introduce new requirements for labor as well as training, supervision, and quality control.
This situation highlights a major purpose for robotic automation. Robotics doesn’t just mean replacing people with a machine. A suitable application can alter the way manufacturers utilize their capacity to produce.
Image credit: automatedsolutions.com.au
Take a look at the time that passes between products
Manufacturing inefficiency doesn’t need to be a major issue. Imagine that an operator has spent 15 seconds arranging the component after which another 10 seconds are spent applying material, and several more seconds to transfer it to the next process. On one component the difference appears to be insignificant. If repeated thousands of times however the seconds could increase production by a significant amount.
It’s the same for waste materials. The addition of a tiny amount of extra coating or dispensing materials in a huge production run can result in an enormous expense.
Before deciding on the equipment that they will require, companies looking at robotic automation Australia will benefit from studying these small losses. The needs analysis conducted by ASA is designed to pinpoint bottlenecks, as well the quality of work, waste and other process limitations that could affect an automation project.
A Robot Must Fit the Process Itself
Selecting a robot is only one option in the engineering process. Controls, guardings and tooling, sensor, conveyors and fixtures are also needed. Engineers must consider the reach of the robot and its payload, in addition to how it interacts with its environment and move about.
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 evaluate the system prior to making it operational on the customer’s floor. This is particularly beneficial in situations where space is not available or when new robotics have to integrate into an existing production line.
Painting and Dispensing Show Why Repeatability Matters
Certain manufacturing processes show the importance of controlled movement particularly well. Imagine coating hundreds or thousands of parts. The end goal isn’t simply finishing each part quickly. It is crucial to manage the speed, distance, and movement of each part from beginning to final.
Our specialists have experience painting and dispensing across different industries such as automotive and aerospace. In these settings, industrial robotic automation can offer repeatable programming and reduce exposure of employees to physically demanding or potentially hazardous processes.
A better management of the waste material can also help improve productivity by cutting down on the amount of waste material used.
Installation of the system isn’t enough. It is still necessary to have people to take care of it.
Automation is not a complete solution to the need for manufacturing expertise. Automation changes the skills needed for maintaining and operating the manufacturing process.
Employees should be aware of how to operate equipment in a safe manner identify abnormal behavior, troubleshoot faults, and perform appropriate maintenance. The production requirements can also alter, which means that the processes and programs could require modifications later.
ASA offers training on site that covers programming, safe operation, troubleshooting, and electrical and mechanical maintenance. The company offers servicing and assistance for assessing equipment condition, and addressing wear throughout the lifetime of the system.
Capacity is more than working faster
The expansion of capacity for Australian manufacturers doesn’t necessarily need to mean purchasing a larger facility or adding more workers on repetitive processes. Sometimes, the most important thing to consider is whether the current manufacturing process could be designed differently.
ASA has been developing and integration of automation solutions since 2002, assisting manufacturers in Australia and also projects in other countries. Its strategy combines analysis of needs as well as engineering simulation. FANUC integration training, and service.
The objective isn’t automation for the sake of it. A system worth the gold it’s worth ought to be able to provide tangible benefits for a manufacturer, such as better production reliability, better quality methods, less risky processes, and less waste.