A big contract is won by a manufacturer. The monthly production needs increase, but the factory isn’t equipped with more space, employees with experience, or extra hours during the daytime. Adding another shift might help temporarily, but it can be a source of new labor as well as training, supervision and quality control requirements.
These scenarios reveal an important reason for robotic automation. Robotics isn’t only about replacing human beings with machines. If it is used correctly, it can change how manufacturers make use of the resources they have.
Image credit: automatedsolutions.com.au
Look at the seconds that disappear between products
Inefficiency in manufacturing isn’t always so dramatic. Imagine an operator spending 15 seconds looking for a particular component, 10 seconds applying the material, then several seconds transfer it. On one component, the difference seems insignificant. If repeated thousands of times these seconds can add significant production time.
This is also true of wasted material. Multiplying a small amount of extra coating or dispensing materials over a long production run can result in substantial costs.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. The needs analysis of ASA is designed to pinpoint bottlenecks, quality issues, waste, as well as other limitations to process that may affect an automation project.
Robots should be able to fit into the process.
A robot is just one of the many engineering choices. Tooling, guardings, controls as well as conveyors, sensors and fixtures are also necessary. Engineers should consider the reach of the robot and its payload, and how it interacts with its environment and how it will move.
ASA offers conceptual development, design of systems and offline programming in its method of robotic automation. Digital simulation allows engineers to examine configurations and estimate the time-to-market before the system is operating in the factory of the customer’s. That becomes particularly useful when space is constrained or when new robotics need to be integrated with a production line that is already in place.
The importance of consistency in painting and dispensing
Controlled movement is crucial for certain manufacturing processes. Imagine coating hundreds or thousands of parts. It’s not enough just to finish every component in a short time. From the time of beginning production all the way to the finish the speed, movement, distance and application must be controlled.
ASA is a specialist in painting and dispensing systems across a range of industries including automotive as well as aerospace. In these industries, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physical demands or potentially dangerous processes.
A better control system can also help reduce excessive material consumption, thereby contributing to less waste, as well as productivity gains.
Even after installation the system requires people
Automating doesn’t completely eliminate the requirement for manufacturing knowledge. The capabilities required to operate, maintain, and run the process change.
Employees should be able recognize unusual behavior and resolve problems, as well as carry out the correct maintenance. Processes and programs can be adjusted later if the production needs shift.
ASA offers training on-site in safe operation, programming and troubleshooting, in addition to mechanical and electrical maintenance. The company provides servicing and assistance for assessing the condition of equipment, and dealing with wear and tear throughout the life of the system.
Capacity Is About More Than the ability to work faster
In Australia, expanding production capacity does not necessarily mean adding workers to repetitive tasks or purchasing larger structures. The better question to ask is whether the existing manufacturing process could be improved.
ASA has been working on and the integration of automation systems since 2002, and has been supporting companies in Australia as well as projects around the world. Its approach connects needs analysis, engineering, simulation, FANUC robot integration, training, and servicing.
Automation is not the goal. A system that is worth its weight in gold will offer tangible benefits to manufacturers, for example higher reliability in production, improved quality process, more secure processes and less waste.