A company is awarded a large contract. Its monthly production needs are increased, but the manufacturing facility hasn’t seen a sudden increase in flooring space, skilled workers, or hours in the daytime. While adding another shift might temporarily boost production, it could also create new jobs or supervision, as well as additional training and quality-control needs.
This situation reveals a key reason for robots. Robotics doesn’t just mean replacing human workers with machines. If it is used correctly it can alter how producers use the capacity they already have.
Image credit: automatedsolutions.com.au
Check out the seconds that disappear between products
Manufacturing inefficiency doesn’t have to be noticeable. For instance, suppose an operator is spending 15 seconds arranging a part and then 10 seconds putting it in material, and several more minutes transferring it to the next process. The difference may seem insignificant for a single component. If repeated thousands of times the seconds could create significant production time.
The same applies to wasted material. The same is true for waste material.
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 find bottlenecks, problems with quality, waste as well as other limitations to process that may affect an automation project.
The robot should fit the system around it.
The choice of a robotics system is only one of the decisions in engineering. The system could also require tooling, guarding, controls, sensors fixtures, conveyors, electrical integration, and communications 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 the surrounding.
ASA offers conceptual development, system design, CAD simulation and offline programming as part of its approach to FANUC robotic automation. Digital simulation allows engineers to test configurations and estimate cycles before the system is put into operation at the customer’s factory floor. This is especially useful when space is constrained or when new robotics need to be integrated into an existing production line.
The importance of repeatability when painting and dispensing
Certain manufacturing processes show the importance of controlling movements. Imagine coating hundreds, or thousands of parts. The desired result isn’t merely finishing each part quickly. The distance, movement speed, and the application must be managed starting from the beginning of the production run to the point of completion.
Our specialists have experience dispensing and painting across various industries including aerospace and automotive. In these industries, industrial robotic automation provides predictable, controlled movements. It also decreases the risk of exposure for employees to physically challenging or potentially hazardous processes.
An improved control over the waste material can also increase productivity by reducing the amount of unnecessary material used.
The System Will Still Need People After Installation
Automation doesn’t eliminate the requirement for manufacturing knowledge. It changes the skills required to run and maintain the manufacturing process.
Employees should be able detect abnormal behavior and identify problems, as well as carry out the correct maintenance. The production requirements can also alter, indicating that programs and processes may need adjustments later on.
ASA provides on-site training in safe operation, programming, troubleshooting, in addition to maintenance of electrical and mechanical systems. The company also provides servicing and ongoing support to monitor the condition of equipment and to address issues that may arise during the equipment’s operational lifespan.
Capacity is the capacity to work faster
An increase in capacity for Australian manufacturers does not necessarily mean buying a bigger building or adding additional labor on repetitive processes. The best question to ask is whether the current manufacturing process could be improved.
ASA has been creating and integrated automation solutions since 2002. It provides support to manufacturers in Australia as well as international projects. Its approach combines analysis of needs with engineering, simulations FANUC robotic integration, training, as well as servicing.
The goal isn’t to automate for the sake of it. A system that is worthy of the gold it’s worth will be able to provide tangible benefits for manufacturers, for example more reliable production, better quality process, more secure processes and less waste.
