A company is awarded a significant contract. The monthly production demands increase, yet the factory hasn’t seen a sudden increase in floor space, experienced employees or hours of work per day. An increase in production for a short period is possible, but adding another shift can introduce new demands for labor as well as training, supervision, and quality control.
Image credit: automatedsolutions.com.au
This situation reveals a key purpose for robotic automation. Robotics isn’t only about replacing human beings with machines. The right software can change the way that manufacturers use their production capacity.
Examine the Seconds That Change Between Products
Manufacturing inefficiency doesn’t have to be dramatic. A worker could spend 15 minutes putting the part in place and then 10 seconds putting on materials, and a few seconds more to move it to the next step. The difference might seem small for a single part. If repeated thousands of times, but those seconds turn into important production times.
The same is true for wasted material. The same is true for waste material.
Before deciding on the equipment that they require, companies considering robotic automation Australia could benefit from analyzing these tiny losses. ASA’s analysis of needs is designed to reveal problems with quality and bottlenecks as in addition to additional constraints and waste during a project.
The robot needs to be able to accommodate the process around it
The decision to choose a robot represents only one decision in engineering. The system might also require guarding, tooling and controls, sensors fixtures, conveyors, electrical integration, and communication with the existing production equipment. Engineers must consider the payload, reach and range as well as how the robot is going to move and interact with its surroundings.
ASA provides the ability to develop concepts, system design and offline programming in its method of robotic automation. Digital simulation lets engineers investigate configurations and estimate cycle times before the completed system is operating at the factory floor of the customer’s. It is particularly helpful when there is a small amount of space, or when the new robotics requires integration with the production line.
Paint and Dispensing demonstrates why Replicability is Important
Controlled movement is essential in some manufacturing processes. Imagine coating hundreds of parts. It’s not enough just to finish each part in a short time. The distance, movement, rate, and even the application needs be managed from the beginning of the production run to the time of its completion.
ASA has experts who work with dispensing applications and paint across various industries, including aeronautics, 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 control of waste material can also help improve productivity by cutting down on the amount of waste materials used.
The installation of the system isn’t enough. It is still necessary to have people to keep it running.
Automation does not completely eliminate the requirement for expert manufacturing. It changes the skills required to operate and maintain the process.
Employees should be trained to safely use equipment, identify abnormal behavior or malfunctioning components, and take care of any maintenance that is required. The demands for production can shift over time, which means that processes and programs will need to be adapted.
ASA offers training on site including programming, safety troubleshooting, and electrical and mechanical maintenance. The company provides ongoing maintenance and services to ensure that the equipment is in top repair and wear and tear problems are dealt with.
Capacity is more than just working more quickly
An increase in capacity for Australian manufacturers doesn’t always require the purchase of a larger building or adding more employees to repetitive processes. One of the best questions to ask is whether the current manufacturing process could be improved.
ASA has been developing and integrating automation solutions in Australia since 2002. We also support projects overseas. Its strategy combines analysis of needs along with engineering simulation FANUC integration as well as training and maintenance.
Automation for the sake of automation isn’t the objective. An investment in a system must provide the manufacturer with measurable outcomes, such as more reliable production, higher quality, more secure procedures as well as reduced waste or a higher capacity.