A manufacturer is awarded a large contract. Although the monthly production requirements have risen, the manufacturing facility doesn’t suddenly have more flooring or experienced workers. A temporary increase in production is possible, but an additional shift may bring new demands for labor training, supervision, and quality control.
This situation highlights a major motive behind robotic automation. It’s not just about replacing human beings with machines. The right software can change the way in which manufacturers make use of their production capacity.
Image credit: automatedsolutions.com.au
Check out the seconds between products
Inefficiency in manufacturing doesn’t have to be evident. An operator could spend 15 seconds positioning the component and then 10 seconds putting on materials, and a few seconds to move it to the next step. With a single component the difference is insignificant. The seconds add up when multiplied by thousands.
Material that has been wasted isn’t different. A small amount of excess coating or dispensing material multiplied throughout a production run that is high-volume could be a substantial expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. The analysis provided by ASA is designed to reveal bottlenecks and quality issues, as also waste and other constraints in a project.
A Robot has to fit the Process Itself
The choice of a robotics system is just one aspect of engineering. It is possible to incorporate tooling, security and controls, sensors as well as conveyers, fixtures electrical integration and communication with existing production equipment. Engineers must consider the robot’s reach and payload, and how it will interact with its environment and move around.
ASA’s approach for FANUC robot automation includes concept development, system design along with CAD Simulation and offline Programming. The digital simulation allows engineers analyze configurations, estimate cycles times and test the system prior to making it in operation on the floor of the customer’s. This is especially helpful when there is a shortage of space or when a new robot needs to be integrated with existing production lines.
It is crucial to have repeatability in painting and dispensing
Certain manufacturing processes highlight the importance of controlled movement particularly well. Imagine coating hundreds of parts. It’s not just about completing the components quickly is the goal. The motion, distance, speed, and application have be controlled at the beginning of the production process until the final.
ASA has specialists working with painting and dispensing systems across a range of industries including automotive as well as aerospace. In these settings, industrial robotic automation allows for the ability to repeat, programmed, and controlled movements. It also reduces exposure of employees to physically challenging or potentially dangerous processes.
Better control may also reduce the amount of material used, which can lead to less waste, as well as productivity improvements.
Even after the installation the system will still require individuals
Automation doesn’t substitute for manufacturing expertise. It requires new skills to run and maintain the process.
Employees should be able to detect abnormal behavior and identify problems, as well as carry out the correct maintenance. Production requirements can also alter, which means that the processes and programs could require modification later.
ASA offers training on site that covers safe operation, programming troubleshooting, and electrical and mechanical maintenance. The company provides ongoing maintenance and repairs to ensure that equipment is in good order and wear and tear issues are dealt with.
Capacity Is About More Than working faster
For Australian producers, expanding capacity doesn’t always mean purchasing a larger building or continually adding labor to repetitive processes. Sometimes, the more important question is whether the existing production process can be redesigned differently.
ASA has been working on and integrating automation solutions since 2002, supporting manufacturers in Australia and also projects internationally. Its method combines analysis of needs, engineering, simulations, FANUC robotic integration training, as well as maintenance.
Automating just for the sake of it isn’t the main goal. A system that is worth its weight in gold ought to be able to provide tangible benefits for an enterprise, including higher reliability in production, improved quality manufacturing processes, and safer ones. It also means less waste.