A manufacturing company gets a large contract. The production requirements for the month increase however, the plant isn’t equipped with more space or employees who have experience or additional hours in the day. While adding a second shift could temporarily boost production, it could also create new jobs, supervision, training and the need for quality control.
Image credit: automatedsolutions.com.au
These situations reveal a very important reason for robotic automation. Robotics does not only mean replacing human beings with machines. It’s a tool that can alter the method by which manufacturers use their existing capacity for production.
Take a look at the time intervals between the products
Manufacturing inefficiency doesn’t have to be dramatic. A worker may take 15 seconds positioning the component and then 10 seconds putting on materials, and a couple of seconds moving it to the next step. On one aspect the difference appears to be insignificant. Those seconds add up when multiplied by thousands.
It’s the same for waste materials. A small amount of excess coating or dispensing material multiplied over a large-scale production run can become a meaningful expense.
Before making a decision on the equipment they will require, companies looking at robotic automation Australia can gain from analysing the small loss. The needs analysis conducted by ASA is designed to find bottlenecks and waste, quality issues and other limitations to process that can affect the automation project.
A Robot has to fit the Process Itself
A robot is one of the many engineering choices. The system might also require tools, guarding, controls, sensors, conveyors, fixtures, electrical integration, as well as communication with existing production equipment. Engineers need to consider the reach and payload of the robot while making decisions about how the robot can move around its space and interact with the environment surrounding it.
ASA provides conceptual development, design of systems and offline programming as part of its approach to robotic automation. Engineers can investigate system configurations and estimate cycles before the system is finally installed on the factory floor. It’s especially useful when there’s a finite area or new robotics needs to integrate with an existing production line.
Dispensing and painting demonstrate why Replicability is Crucial
Certain manufacturing processes highlight the importance of controlled motion particularly well. Imagine coating hundreds or even thousands of components. It’s not just about completing the components quickly is the desired outcome. It’s crucial to regulate the speed, distance, and the movement of every component from the beginning until the final.
Our specialists have experience painting and dispensing across different industries like aerospace and automotive. In these environments, industrial robotic automation can provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially hazardous processes.
Better control may also reduce unnecessary material consumption, contributing to less waste, as well as productivity enhancements.
The System Needs Personnel After Installation
Automatism doesn’t replace manufacturing knowledge. It transforms the knowledge needed to run and maintain the manufacturing process.
Employees need to know how to operate equipment in a safe manner be aware of abnormal behavior, troubleshoot faults, and conduct the necessary maintenance. The production needs can change as time passes, which means that processes and programs will require adjusting.
ASA provides training on site in safe operation, programming and troubleshooting. It also offers maintenance of electrical and mechanical systems. The company offers ongoing maintenance and services to ensure that equipment is in good condition and wear and tear issues are dealt with.
Capacity is more than just working faster
In Australia, increasing production capacity does not always mean adding more employees to repetitive jobs or buying bigger structures. Sometimes the better question is whether the current manufacturing process could be designed differently.
ASA has been creating and integration of automation solutions since 2002. It assists manufacturers in Australia as well as international projects. Its approach combines the analysis of requirements and engineering, simulations, FANUC robotic integration, training, as well as servicing.
Automation is not the goal. Any system that is worth investing in must provide the manufacturer with measurable results, which include increased reliability of production, improved quality, more secure procedures as well as reduced waste or a higher capacity.