A manufacturer wins a major contract. Although the monthly production requirements have increased, the factory does not have an increase in floor space or experienced employees. The addition of a second shift could help temporarily, but it may also introduce new labor and training, supervision, and quality-control regulations.
Image credit: automatedsolutions.com.au
Situations like this reveal an important purpose of robotic automation. Robotics does not only mean replacing human workers with machines. The right software can change the way that manufacturers use their capacity to produce.
Have a look at the amount of time that is lost between products
Manufacturing inefficiency isn’t always evident. Imagine a worker taking 15 seconds searching for a piece of equipment after which they spend 10 seconds putting the material, then several seconds transferring it. On a single part, the difference is insignificant. Repeated thousands of times these seconds can turn into significant production time.
Same goes for waste material. Same goes to waste materials.
Companies that are considering robot automation Australia projects will benefit from examining these small frequent losses prior to choosing the right equipment. ASA’s needs analysis aims to pinpoint bottlenecks, as well problems with quality, waste and other process limitations that can affect the automation project.
Robots should be able to work with the system.
The decision to choose a robot is only one of the decisions in engineering. It could be necessary to add tooling, guarding and controls, sensors, conveyers, fixtures, electronic integration, and communications with the current production equipment. Engineers must take into consideration the robot’s reach and payload, as well as how it will interact with its environment and move about.
ASA provides concepts development, design, CAD simulation and offline programming as part of its plan to FANUC’s robotic automation. Engineers can look at system configurations and estimate the number of cycles required before the finished system is installed on the floor of the factory. This is especially useful when space is limited or if new robotics need to be integrated with the existing lines of production.
The importance of consistency in painting and dispensing
Certain manufacturing processes show the importance of controlled movements. Imagine applying a coating to hundreds of components. The goal isn’t just complete each component at a rapid pace. From the start of production until the final stage all the movements, speed and distance must be managed.
Our specialists have experience dispensing and painting across various industries including aerospace and automotive. In these settings, industrial robotic automation can ensure that the same program is repeated while also reducing employee exposure to physically demanding or hazardous processes.
Reduced waste and the improvement of productivity can be accomplished through better control.
Even after the installation, the system still requires individuals
Automation doesn’t eliminate the need for manufacturing expertise. Automation alters the knowledge required to maintain and operate the process.
Employees should be able to spot abnormal behavior and solve issues, and carry out the correct maintenance. Production requirements can alter, which means that procedures and programs might require adjustments later on.
ASA offers on-site training in safe operation, programming troubleshooting, and mechanical and electrical maintenance. Additionally, the company provides maintenance and ongoing support to check equipment condition and address wear over the system’s operating time.
Capacity goes beyond just working faster
For Australian manufacturers, increasing capacity doesn’t mean purchasing larger buildings or adding workers to repetitive processes. Sometimes, the more important question is whether the current production process can be redesigned differently.
ASA has been developing and integrating automation solutions in Australia since 2002. We also support projects in other countries. Its methodology combines the analysis of requirements, engineering, simulations, FANUC robotic integration and training and even servicing.
Automation for the sake of automation isn’t a goal. An investment in a system should provide a company with quantifiable outcomes, such as better production reliability, higher quality, safer procedures, reduced waste or increased capacity.