A manufacturing company wins a big contract. Even though the production needs for each month have grown, the plant isn’t suddenly equipped with more floor space or experienced employees. While adding a second shift could temporarily boost production, it could also create new jobs as well as training, supervision, and the need for quality control.
This situation highlights a major reason for robots. Robotics doesn’t just replace humans with machines. It is able to alter the method by which manufacturers use their production capacity.
Image credit: automatedsolutions.com.au
Watch the second-to-second time between products
Inefficient manufacturing isn’t always obvious. If an operator takes 15 minutes putting a piece of equipment in place after which another 10 seconds are spent applying materials, and then several minutes transferring it to the next process. The difference might seem small even for a single piece of equipment. If repeated thousands of times these seconds can result in significant production delays.
Same goes for waste material. A tiny amount of leftover coating or dispensing material multiplied across a high-volume production run could result in a significant expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. ASA’s analysis of requirements is designed to pinpoint problems with quality and bottlenecks, as in addition to any other limitations in a plan.
A Robot Has to Fit the Process Around It
A robot is just one of the many engineering choices. The system will also require tools, guarding control, sensors fixtures, conveyors, electrical integration, and communication with the existing production equipment. Engineers should think about the payload, reach and range as well as how the robot will move and interact with its surroundings.
The FANUC approach of ASA’s approach to robot automation is based on concept development and system design along with CAD Simulation and offline programming. The digital simulation allows engineers to to explore the possibilities of configurations, estimate cycle times and test the system before it becomes in operation on the floor of the customer’s. This is particularly helpful when space is limited or when a new robot needs to be integrated into the existing lines of production.
Paint and Dispensing Shows Why Replicability is Essential
Certain manufacturing processes highlight the benefits of controlled movement especially well. Imagine coating hundreds or thousands of components. The goal isn’t just finishing each part quickly. The distance, movement, speed, and the application must to remain controlled starting from the beginning of the production run to the point of completion.
ASA has experts who work on dispensing and paint applications across all industries, including automotive and aeronautics. In these areas, industrial robotic automation provides the ability to repeat, programmed, and controlled movements. It also reduces exposure of employees to physically challenging or potentially dangerous processes.
A better management of waste material can also aid in productivity improvement by decreasing the amount of unneeded materials used.
Even after installation the system requires individuals
Automation does not completely eliminate the need for manufacturing expertise. Automation can alter the capabilities needed to manage and control the manufacturing process.
Employees should be able to detect abnormal behavior and identify issues, and carry out the correct maintenance. Production requirements can also be changed, which means the processes and programs could require adjustments later on.
ASA provides training on site in safe operating, programming, and troubleshooting as well as electrical and mechanical maintenance. The company provides continuous maintenance and servicing to ensure that equipment is in good working order and wear and tear issues are dealt with.
Capacity is about more than the ability to work faster
For Australian manufacturers, increasing capacity doesn’t always mean purchasing larger buildings or increasing the amount of labor required to perform repetitive tasks. It’s often better to ask if the production process can be improved.
ASA has been working on and integrating automation solutions since 2002. It has assisted companies in Australia and projects internationally. Its methodology combines the analysis of requirements as well as engineering, simulations FANUC robotic integration training, and even servicing.
The goal isn’t to automate for the sake of it. A system worthy of its weight in gold should offer tangible benefits to an enterprise, including more reliable production, better quality, safer processes and less waste.
