A manufacturer is awarded a large contract. Although the monthly production requirements have increased, the facility does not have an increase in flooring or experienced workers. Although adding another shift may temporarily aid, it might also create new jobs in the form of supervision, training, or the need for quality control.
These situations reveal a very important reason for robotic automation. Robotics doesn’t just mean replacing human beings with machines. It is able to modify the methods that manufacturers employ to use their existing production capacity.
Image credit: automatedsolutions.com.au
You can check out the time difference between products
Inefficient manufacturing may not be obvious. A worker could spend 15 minutes putting the part in place after which 10 seconds are spent applying materials, then a few more seconds moving it onto the next stage. The difference may seem insignificant for a single part. When repeated thousands of times however, these seconds can increase production by a significant amount.
This is also true of wasted material. A tiny amount of leftover coating or dispensing material that is multiplied throughout a production run that is high-volume could result in a significant expense.
Companies considering robotic automation Australia projects can benefit from examining these small, repeated losses before deciding what equipment they need. ASA’s needs analysis is designed to pinpoint bottlenecks, quality issues, waste, and other process constraints which could affect the automation project.
Robots should be able to be integrated into the process.
Selecting a robot is only one of the engineering decisions. The system might also require tools, guarding and controls, sensors fixtures, conveyors, electrical integration, and communication with existing production equipment. Engineers must consider reach and payload when making decisions about how the robot will move about its workspace and interact with the environment around it.
ASA offers conceptual development, design of systems and offline programming as part of its method of robotic automation. Engineers are able to explore configurations for the system and estimate cycle times before the system is finally installed on the factory floor. This is especially helpful when there is a shortage of space or when new robotics have to be integrated into existing production lines.
Painting and dispensing show why Repetability is Important
Controlled movement is especially important in certain manufacturing processes. Imagine coating hundreds or even thousands of components. It’s not just about completing the components quickly is the goal. The movement, distance, rate, and even the application needs be managed starting from the beginning of the production run to the time of its completion.
ASA is a specialist in painting and dispensing systems across industries including automotive and aerospace. In these industries industrial robotic automation may provide repeatable programmed movement while also reducing employee exposure to physically demanding or potentially dangerous processes.
A better control system can also help reduce excessive material consumption, thereby contributing to a reduction in waste and productivity enhancements.
The installation of the system isn’t enough. Still, you need someone to manage it.
Automation does not eliminate the need for expertise in manufacturing. Automation transforms the skills required to operate and maintain the process.
Employees should be trained to operate equipment in a safe manner, identify abnormal behavior, troubleshoot faulty components, and complete any necessary maintenance. The production needs can change in time, meaning that processes and programs will need to be adjusted.
ASA offers training on-site in safe operation, programming and troubleshooting as well as mechanical and electrical maintenance. The company provides continuous maintenance and services to ensure that equipment is in good condition and wear and tear issues are addressed.
Capacity is about more than simply working faster
The expansion of capacity for Australian manufacturers does not necessarily mean buying a bigger building or adding more employees to repeat processes. It’s often better to inquire if the manufacturing procedure could be altered.
ASA has been creating and integrated automation systems since 2002, assisting manufacturers in Australia and projects internationally. Its approach connects needs analysis, engineering, simulation, FANUC robot integration Training, and servicing.
Automation is not the only goal. A system that is worthy of its weight in gold must be able to provide tangible benefits for a manufacturer, such as higher reliability in production, improved quality, safer processes and less waste.