A company is awarded a significant contract. While the demands for production have risen, the manufacturing facility isn’t suddenly equipped with more floor space or experienced employees. Adding another shift might help temporarily, but it can be a source of new labor, training, supervision, and quality-control requirements.
This situation highlights a major need for robotic automation. It’s not just about replacing human beings with machines. The right software can change the way manufacturers utilize their capacity to produce.
Image credit: automatedsolutions.com.au
Check out the Seconds that Aren’t able to be found between the products
Manufacturing inefficiency isn’t always evident. An operator may spend 15 minutes positioning the item after which 10 seconds are spent applying materials, then a few more seconds moving it onto the next stage. On one component it’s not much of a difference. If repeated thousands of times, the seconds are significant production time.
Material that has been wasted isn’t different. The same is true of waste materials.
Companies looking into robot automation Australia projects will benefit from studying these tiny, repeated losses before making a decision on the equipment they require. The needs analysis of ASA is designed to find bottlenecks, quality issues, waste, and other constraints to the process that can affect an automation project.
The robot should fit the procedure around it.
Robots are just one of many engineering choices. Tooling, guardings, controls, sensor, conveyors and fixtures might also be necessary. Engineers should think about reach, payload and how the robot will operate and interact with its environment.
ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. Digital simulation allows engineers to explore configurations and estimate cycles before the system can be put in operation in the factory of the customer’s. This is especially useful when there are space constraints or if new robotics need to be incorporated into existing production lines.
Painting and Dispensing demonstrates why the importance of repeatability is evident.
Some manufacturing processes demonstrate the importance of controlled movement particularly well. Imagine applying a protective coating to hundreds of components. It’s not just about completing the components quickly is the desired outcome. It is crucial to manage the speed, distance, and movement of each piece from beginning to very end.
ASA’s specialists are experienced in painting and dispensing across industries including aerospace and automotive. In these areas, industrial robotic automation allows for predictable, controlled movements. It also reduces exposure of employees to physically challenging or potentially hazardous processes.
A better control of waste materials can also contribute to productivity improvements by decreasing the amount of unneeded materials used.
The System Still Needs People Even After Installation
Automatism isn’t a substitute for manufacturing knowledge. Automation transforms the skills required to manage and control the manufacturing process.
Employees must be able to operate equipment safely and recognize any abnormalities or malfunctions, then troubleshoot the issue and conduct the necessary maintenance. The processes and procedures can be adjusted later if production requirements are changed.
ASA provides on-site training covering programming, safe operation, troubleshooting, as well as electrical and mechanical maintenance. The company also provides regular maintenance and service to ensure that equipment is in good order and wear and tear issues are addressed.
Capacity means more than just getting faster work done
For Australian producers, expanding capacity doesn’t necessarily mean buying a larger building or continually increasing the amount of labor required to perform repetitive tasks. Sometimes, the most important thing to consider is whether or not the existing production process can be redesigned differently.
ASA has developed and integrated automation systems in Australia since 2002. We also support projects overseas. Its method combines analysis of needs with engineering, simulations FANUC robotic integration and training as well as servicing.
Automation isn’t the goal. A good system will give a manufacturer something measurable in terms of increased reliability and quality, as well as safer procedures, less waste or a greater capacity in the existing factory.