A company is awarded a significant contract. Production requirements for the month increase, but the factory does not suddenly gain floor space, experienced employees, or hours in the day. Although adding another shift may temporarily boost production, it could also bring new labor or supervision, as well as additional training and requirements for quality control.
These kinds of situations reveal an important purpose of robotic automation. Robotics doesn’t just mean replacing humans with machines. The right software can change the way manufacturers utilize their production capacity.
Image credit: automatedsolutions.com.au
Have a look at the amount of time that is lost between products
Inefficiency in manufacturing isn’t always so dramatic. Imagine an operator spending 15 seconds locating a component and then 10 seconds putting it into the material, then several seconds transfer it. On one component, the difference seems insignificant. It’s a lot when multiplied by thousands.
It’s the same for waste materials. A small amount of extra coating or dispensing material that is multiplied throughout a production run that is high-volume can become a meaningful expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. AAS’s Needs Analysis aims to uncover bottlenecks as well quality issues, waste and other processes that can affect the automation project.
The robot needs to be able to accommodate the procedure around it.
The choice of a robotics system is just one aspect of engineering. Tools, guardings, controls sensors, conveyors and fixtures could also be necessary. Engineers should think about the payload, reach and range as well as how the robot will move and interact in the environment.
ASA’s approach to FANUC robot automation includes concept development and system design, CAD Simulation, and offline programming. The digital simulation allows engineers analyze configurations, estimate cycles times and 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 when the new robotics is required to be integrated with the production line.
It is crucial to have repeatability in painting and dispensing
Controlled movement is especially important in some manufacturing processes. Imagine coating hundreds of parts. Not just completing components quickly is the desired outcome. From the moment of starting production until the final stage all the movements, speed, distance and application must be controlled.
ASA has experts working on painting and dispensing applications across various industries, including automotive and aerospace. Industrial robotic automation in these industries allows for reproducible movements while limiting exposure of workers to physically demanding processes or ones that may cause harm.
A better management of waste material can also help improve productivity by reducing the amount of unnecessary material used.
Even after the installation the system requires people
Automation doesn’t eliminate the need for skilled manufacturing. It changes the skills required to run and maintain the process.
Employees should be able detect abnormal behavior and identify issues, and carry out the correct maintenance. The needs for production may change with time, which means that programs and processes will require adjusting.
ASA offers training on site that covers safe operation, programming, troubleshooting, and electrical and mechanical maintenance. The company offers ongoing maintenance and repairs to ensure that equipment is in top order and wear and tear problems are dealt with.
Capacity is about more than just working faster
In Australia, increasing production capacity doesn’t always mean adding more employees to repetitive jobs or purchasing bigger buildings. Sometimes, the best question is whether or not the existing production process can be redesigned differently.
ASA has been working on and integration of automation solutions since 2002, and has been supporting companies in Australia and also projects around the world. The company’s strategy combines analysis of needs, engineering, simulation, FANUC robot integration Training, and servicing.
Automation is not the only goal. An investment-worthy system must provide the manufacturer with measurable results, including more reliable production, higher quality, safer methods as well as reduced waste or a higher capacity.