A large contract is signed by the manufacturer. The monthly production demands rise, but the facility isn’t gaining area for floor, skilled employees or working hours during the daytime. While adding another shift might temporarily aid, it might be a source of new work, supervision, training and requirements for quality control.
These situations reveal a very crucial reason for robot automation. Robotics doesn’t just mean replacing human workers with machines. A good application could change the way manufacturers utilize their capacity to produce.
Image credit: automatedsolutions.com.au
Watch the second-to-second time between products
Manufacturing inefficiency isn’t always noticeable. Imagine a worker spending 15 minutes searching for a part for 10 seconds, then applying the material and then moving it. On one piece it’s not much of a difference. Repeated thousands of times these seconds can turn into substantial production time.
It’s the same with scrap material. A small amount of extra coating or dispensing material that is multiplied over a large-scale production run 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. ASA’s needs analysis aims to uncover bottlenecks as well quality issues, waste and other process limitations that might affect an automation plan.
The robot must fit the procedure around it.
Selecting a robot is only one decision in engineering. Tooling, guardings, controls, sensor, conveyors and fixtures may also be required. Engineers must consider reach, payload and how the robot will move and interact in its environment.
The FANUC approach of ASA’s approach to robot automation encompasses concept development, system design including CAD Simulation, offline Programming. Digital simulation lets engineers examine configurations, estimate cycle times and test the system before it is operational on the customer’s floor. This is especially helpful when there are space constraints or if new robotics need to be integrated with the existing lines of production.
Painting and Dispensing demonstrates why Repeatability Matters
Some manufacturing processes illustrate the importance of controlled motion especially well. Imagine applying a protective coating to hundreds of parts. The end goal isn’t simply finishing each part quickly. It is important to control the speed, distance, and movement of each part from beginning to final.
ASA has specialists working with painting and dispensing systems across a range of industries including automotive as well as aerospace. Industrial robotics automation in these areas can allow for repeatable movements while reducing the exposure of workers to physical demanding processes or procedures that could risk injury.
Controlled better can reduce unnecessary material consumption, contributing to a reduction in waste and productivity enhancements.
Even after installation the system requires people
Automation does not completely eliminate the need for expertise in manufacturing. The abilities needed to operate, maintain, and control the process evolve.
Employees must be taught to operate equipment in a safe manner and to recognize abnormal behavior and troubleshoot malfunctioning components and complete any necessary maintenance. Production requirements can change over time, which means that processes and programs will require adjusting.
ASA offers on-site training in safe operation, programming troubleshooting, as well as electrical and mechanical maintenance. The company offers servicing and assistance for assessing the condition of equipment and taking care to address wear throughout the lifetime of the system.
Capacity means more than just making work faster
For Australian manufacturers, increasing capacity doesn’t necessarily mean purchasing more space or adding labor to repetitive processes. Sometimes, the more important question is whether the existing manufacturing process could be designed differently.
ASA is designing and integration of automation solutions since 2002. It works with companies in Australia and international projects. Its methodology combines analysis of needs as well as engineering, simulations FANUC robotic integration training, and also servicing.
Automating just for the sake of it isn’t the objective. An investment-worthy system will provide a manufacturer with tangible results, which include greater reliability in production, better quality, more secure procedures as well as reduced waste or a higher capacity.