A manufacturer wins a major contract. Monthly production requirements increase, yet the factory hasn’t seen a sudden increase in floors, employees with experience, or hours in the daytime. A temporary increase in production could be possible, however an additional shift may bring new labor requirements, training, supervision and quality control.
These scenarios reveal an crucial reason for robot automation. Robotics doesn’t just mean replacing humans with machines. It’s a tool that can alter the method by which manufacturers use their existing production capacity.
Image credit: automatedsolutions.com.au
Take a look at the seconds that Aren’t able to be found between the products
Inefficiency in manufacturing doesn’t have to be significant. Imagine that an operator has spent 15 seconds positioning a component for 10 seconds, then another 10 seconds applying material, and then a few minutes transferring it to the next process. On a single part, the difference is insignificant. If repeated thousands of times, the seconds are important production times.
It’s the same with scrap material. A small amount of excess coating or dispensing material that is multiplied over a large-scale production run can result in an expense that is significant.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. The analysis conducted by ASA’s Needs Analysis is designed to find bottlenecks, problems with quality, waste and other process constraints that may affect an automation project.
Robots must be able to be integrated into the process.
A robot is just one of many engineering options. The system will also require guarding, tools, controls, sensors fixtures, conveyors electronic integration, and connectivity with the existing production equipment. Engineers must take into consideration the robot’s reach and payload, and how it interact with its surroundings and move about.
ASA offers conceptual development, design of systems and offline programming as part of its approach to robotic automation. The digital simulation allows engineers to explore configurations, estimate cycle times and test the system before it is in operation on the floor of the customer’s. This is especially helpful when there is a shortage of space or if new robotics require to be incorporated into the existing lines of production.
Dispensing and painting demonstrate why Replicability is Essential
The ability to control movement is particularly important in some manufacturing processes. Imagine applying a coating to hundreds of parts. It’s not enough to complete each piece quickly. The distance, movement, speed, and application have be managed from the start of the production process until the end.
ASA has specialists who work on painting and dispensing solutions across a range of industries including automotive as well as aerospace. In these environments industrial robotic automation allows for predictable, controlled movements. It also reduces employee exposure to potentially dangerous processes.
The reduction in waste and the improvement in productivity can be achieved through better management.
Installation of the system isn’t enough. Still, you need someone to manage it.
Automation is not a complete solution to the need for skilled manufacturing. It changes the skills required to operate and maintain the manufacturing process.
Employees must be able to safely operate equipment be aware of abnormal behavior, troubleshoot faults, and perform appropriate maintenance. The processes and procedures can be modified later on if production requirements change.
ASA provides on-site training in safe operation, programming and troubleshooting. It also offers electrical and mechanical maintenance. The company provides ongoing maintenance and repairs to ensure that the equipment is in top order and wear and tear problems are dealt with.
Capacity is more than working faster
In Australia, expanding production capacity doesn’t always mean adding workers to repetitive tasks or buying larger structures. It’s often better to inquire if the manufacturing process could be redesigned.
ASA has developed and integrated automation solutions in Australia since 2002. We also support projects across the world. Its method of analysis connects needs Engineering, simulation, FANUC robot integration Training, and servicing.
Automation for the sake of automation isn’t the goal. A system worth investing in should provide a company with quantifiable results, like greater reliability in production, better quality, safer processes as well as reduced waste or a higher capacity.