A big contract is won by a manufacturer. While the requirements for monthly production have increased, the factory does not suddenly have more floors or more experienced workers. A second shift may help temporarily, but it could also create new work, training, supervision, and quality-control requirements.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics doesn’t just replace humans with machines. The right software can change the way that manufacturers use their production capacity.
Examine the Seconds That Change Between Products
Inefficient manufacturing isn’t always apparent. If an operator takes 15 seconds arranging the component after which another 10 seconds are spent applying the material, and a few seconds moving it to the next step. On one piece, the difference seems insignificant. When repeated a thousand times the seconds could create significant production time.
It’s the same for waste materials. A small amount of extra coating or dispensing material that is multiplied in a production run with a high volume can become a meaningful expense.
The companies that are considering robotic automation Australia can benefit from analyzing these small routine losses before they decide on the best equipment to buy. ASA’s analysis of requirements is designed to reveal bottlenecks and quality issues as along with any other limitations in a plan.
The robot has to fit the system around it.
The choice of a robot represents only one decision in engineering. It may be necessary to install tooling, protection and controls sensors, conveyers, fixtures, electronic integration, and communications with the current production equipment. Engineers must consider reach and payload when making decisions about how the robot will move about its space and interact with the environment surrounding it.
The FANUC approach of ASA’s approach to robot automation is based on concept development, system design including CAD Simulation, offline programming. Digital simulation allows engineers to test configurations and estimate durations of the cycle before the system is put into operation in the factory of the customer’s. It is particularly helpful when there’s a finite amount of space or the new robotics has to integrate with the production line.
The importance of consistency in painting and dispensing
Controlled movement is crucial for certain manufacturing processes. Imagine covering hundreds of components. The desired result isn’t merely finishing each part quickly. From the time of beginning production through the conclusion all the movements, speed and distance must be controlled.
ASA has experts who deal in the field of dispensing and painting across all industries, including aeronautics and automotive. Industrial robotics automation in these areas allows for reproducible movements while reducing the exposure of employees to physical demands or ones that may be dangerous.
A better control of waste materials can also contribute to productivity improvements by reducing the amount of unnecessary material used.
The installation of the system isn’t enough. It is still necessary to have people to maintain it.
Automation does not completely eliminate the need for expertise in manufacturing. Automation can alter the capabilities needed to operate and maintain the process.
Employees need to be trained to safely use equipment in order to identify any abnormalities as well as troubleshoot components that are malfunctioning and carry out necessary maintenance. The demands for production can shift in time, meaning that procedures and protocols will need to be adjusted.
ASA offers training on site including programming, safety troubleshooting, mechanical and electric maintenance. The company also provides servicing and ongoing support to monitor the condition of the equipment and deal with wear over the system’s operating time.
Capacity is more than working more quickly
An increase in capacity for Australian manufacturing companies doesn’t require the purchase of a larger building or adding additional labor on repetitive processes. Sometimes, the most important thing to consider is whether or not the existing manufacturing process can be designed differently.
ASA has been designing and integrated automation solutions since 2002. It supports manufacturers in Australia, as well as international projects. Its method combines the analysis of requirements, engineering, simulations, FANUC robotic integration and training and even servicing.
The objective isn’t automation just for the sake of automation. A system worth the gold it’s worth ought to provide measurable benefits to a manufacturer, such as greater reliability, higher quality manufacturing processes, and safer ones. It also means less waste.