A company is awarded a significant contract. Although the monthly production requirements have increased, the facility does not suddenly have more area for floor or skilled workers. A temporary increase in production might be possible, but adding another shift can introduce new labor requirements education, supervision, training and quality control.
Image credit: automatedsolutions.com.au
This scenario reveals the primary motive behind robotic automation. Robotics is not just replacing humans with machines. If it is used correctly it could alter the way producers use the capacity they already have.
Take a look at the seconds that Change Between Products
Manufacturing inefficiency doesn’t have to be noticeable. Imagine a worker taking 15 minutes searching for a part, 10 seconds applying the material and several seconds to transfer it. The difference may seem insignificant for one component. If repeated thousands of times, however, those seconds become substantial production time.
The same applies to wasted material. This is also true to waste materials.
Before selecting the equipment they will require, companies looking at robotic automation Australia will benefit from studying these tiny losses. AAS’s Needs Analysis aims to uncover bottlenecks as well the quality of work, waste and other processes that could affect an automation project.
The robot has to fit the procedure around it.
The choice of a robot is just one decision in engineering. It is possible to add tooling, guarding and controls, sensors, conveyers, fixtures, electronic integration, and communications to the production equipment already in place. Engineers need to consider reach and payload when determining how the robot is going to move through its work area and interact with the environment around it.
The FANUC approach of ASA’s approach to robot automation is to use conceptual development and design along with CAD Simulation and offline programming. Engineers are able to explore configurations for the system and calculate cycles prior to when the finished system is installed on the factory floor. That becomes particularly useful when space is limited or new robotics must integrate into an existing production line.
The importance of consistency in painting and dispensing
Some manufacturing processes demonstrate the value of controlled movement especially well. Imagine coating hundreds or thousands of parts. It’s not enough to finish every component quickly. The motion, distance, speed, and application have to be monitored at the beginning of the production line until the end.
The experts at ASA are proficient in dispensing and painting across various industries such as automotive and aerospace. In these environments, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially hazardous processes.
A better management of waste materials can also aid in productivity improvement by reducing the amount of unnecessary material used.
Installation of the system isn’t enough. You will require people to keep it running.
Automation doesn’t substitute for manufacturing expertise. Automation changes the skills needed to operate and maintain the process.
Employees must be taught to operate equipment in a safe manner in order to identify any abnormalities, troubleshoot faulty components, and take care of any maintenance that is required. The production needs can change with time, which means that procedures and protocols will need to be adapted.
ASA offers on-site training in programming, safety troubleshooting, mechanical and electric maintenance. The company offers ongoing maintenance and services to ensure that equipment is in top working order and wear and tear issues are dealt with.
Capacity Is About More Than Working Faster
In Australia, increasing production capacity doesn’t always mean adding workers to repetitive tasks or buying bigger buildings. Sometimes the better question is whether the existing production process can be engineered differently.
ASA has been developing and the integration of automation solutions since 2002. It supports the manufacturing industry in Australia and international projects. Its approach connects needs analysis with engineering, simulation, FANUC robot integration, training, and servicing.
Automation for the sake of automation isn’t the objective. Any system that is worth investing in should offer a manufacturer measurable outcomes, such as greater reliability in production, better quality, more secure procedures with less waste, or a greater capacity.