A company is awarded the contract for a significant amount. While the requirements for monthly production have increased, the factory does not suddenly have more floor space or experienced employees. A second shift may help in the short term, but it could also introduce new labor and training, supervision, and quality-control requirements.
This situation reveals a key reason for robots. Robotics isn’t only about replacing humans with machines. It’s a tool that can transform the way that manufacturers utilize their current production capacity.
Image credit: automatedsolutions.com.au
You can check out the time difference between the products
Inefficiency in manufacturing doesn’t need to be a major issue. A worker may take 15 minutes positioning the item after which 10 seconds are spent applying substances, and then a few seconds more to move it to the next step. For one part it’s not much of a difference. If repeated a thousand times these seconds can add significant production time.
The same applies to wasted material. In the event of spreading a small amount additional coatings or dispensing material across a large production line can lead to a significant expense.
Companies that are considering robot automation Australia projects can benefit from studying these tiny, repeated losses before deciding on the equipment they will require. ASA’s needs analysis is intended to uncover bottlenecks and quality issues, waste, and other constraints to the process that may affect an automation project.
The robot should fit the processes around it.
Robots are just one of many engineering decisions. It is possible to add tooling, guarding and controls, sensors conveyors, fixtures, electrical integration and communication to the production equipment already in place. Engineers should consider the reach, payload and how the robot is going to operate and interact with the environment.
ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. Digital simulation lets engineers investigate configurations and estimate durations of the cycle before the system is operational at the customer’s factory floor. This is especially useful when space is limited or when a new robot needs to be integrated into existing production lines.
Paint and Dispensing Shows Why Replicability is Important
Some manufacturing processes illustrate the importance of controlled motion especially well. Imagine applying a protective coating to hundreds of parts. It’s not enough just to complete each piece in a short time. From the moment of starting production to the end all the movements, speed and distance must be managed.
ASA is a specialist in painting and dispensing solutions across industries including automotive and aerospace. Industrial robotic automation in these industries allows for reproducible movements as well as limiting the exposure of employees to physical demanding processes or ones that may be hazardous.
An improved control over materials that are discarded can aid in productivity improvement by reducing the amount of unnecessary material used.
Installing the system is not enough. It is still necessary to have people to maintain it.
Automation does not eliminate the need for expertise in manufacturing. Automation transforms the skills required to maintain and operate the process.
Employees need to be able recognize unusual behavior and resolve problems, as well as do the proper maintenance. Programs and processes can be adjusted later if production requirements alter.
ASA provides training on site covering safety, programming troubleshooting, electrical and mechanical maintenance. It also offers servicing as well as ongoing support to evaluate equipment condition and address problems that arise over the system’s operational time.
Capacity Is About More Than Being able to work faster
In Australia, expanding production capacity does not always mean adding workers to repetitive tasks or buying larger structures. Sometimes, the more important question is whether the current production process can be engineered differently.
ASA has been creating and integrated automation solutions since 2002. It assists companies in Australia and international projects. Its strategy combines analysis of needs and engineering simulation with FANUC integration along with training and servicing.
Automation is not the goal. A system that is worthy of the gold it’s worth must bring tangible benefits to the manufacturer, like greater reliability, higher quality process, more secure processes and less waste.