A company is awarded a significant contract. The monthly production needs increase however, the plant doesn’t have more space or employees who have experience or extra hours during the daytime. An increase in production for a short period might be possible, but adding another shift can bring new requirements for labor, training, supervision and quality control.
Image credit: automatedsolutions.com.au
This situation highlights a major purpose for robotic automation. Robotics isn’t simply about replacing human beings with the aid of a machine. The right application can transform the way in which manufacturers make use of their production capacity.
Take a look at the seconds that Change Between Products
Inefficient manufacturing is not always obvious. Imagine a person spending 15 minutes searching for a part, 10 seconds applying the material, and then a few seconds moving it. With a single component it’s a small difference. When repeated a thousand times, these seconds can result in significant production delays.
The same applies to wasted material. Multiplying a small amount of extra coating or dispensing materials over a long production run could result in the cost of a large amount.
Businesses considering robotic automation Australia projects could benefit from studying these tiny, repeated losses before choosing the right equipment. The needs analysis conducted by ASA is designed to find bottlenecks and waste, quality issues and other process constraints which could impact an automation project.
The robot has to fit the system around it.
A robot’s selection is only one option in the engineering process. It may be necessary to install tooling, protection and controls sensors, conveyers, fixtures, electrical integration, and communication with existing production equipment. Engineers must consider the robot’s reach and payload, in addition to how it will interact with its environment and how it will move.
ASA offers conceptual development, design of systems and offline programming as part of its approach to robotic automation. The digital simulation allows engineers to analyze configurations, estimate cycles time and allow them to test the system before it is in operation on the floor of the customer’s. It is particularly helpful in situations where there is a restricted amount of space or the new robotics requires integration with an existing production line.
Dispensing and Paint Shows Why Replicability is Crucial
Controlled movement is essential in some manufacturing processes. Imagine covering a variety of components. The desired result isn’t merely finishing each part quickly. From the moment of starting production until the final stage moving, speed as well as the distance to be applied must be managed.
ASA has experts who deal on dispensing and paint applications across all industries, including aeronautics and automobile. In these environments, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially hazardous processes.
An improved control over waste materials can also aid in productivity improvement by cutting down on the amount of waste material consumed.
The System Needs Personnel After Installation
Automation is not a complete solution to the need for expertise in manufacturing. The abilities needed to manage, maintain and control the process evolve.
Employees need to know how to operate equipment in a safe manner identify abnormal behavior, troubleshoot faults, and conduct the necessary maintenance. Processes and programs can be modified later on if production requirements shift.
ASA provides training on site in safe operating, programming, and troubleshooting, as well as mechanical and electrical maintenance. The company provides ongoing maintenance and repairs to ensure that equipment is in good repair and wear and tear problems are dealt with.
Capacity is more than just making work faster
In Australia, expanding production capacity does not necessarily mean adding more employees to repetitive jobs or purchasing bigger buildings. The best question to ask is whether the existing production process can still be improved.
ASA has been working on and integrated automation systems since 2002, supporting manufacturers in Australia and also projects in other countries. Its method of analysis combines needs as well as engineering simulation. FANUC integration along with training and servicing.
It’s not about automation just for the sake of automation. Any system that is worth investing in must provide the manufacturer with measurable results, like more reliable production, higher quality, safer processes and reduced waste, or an increase in capacity.