A company is awarded an important contract. While the demands for production have increased, the facility doesn’t suddenly have more floors or more experienced workers. The addition of a second shift could help in the short term, but it could be a source of new labor, training, supervision, and quality-control demands.

Image credit: automatedsolutions.com.au

Situations like this reveal an important purpose of robotic automation. Robotics doesn’t just replace humans with machines. The right software can change the way that manufacturers use their capacity to produce.

Take a look at the seconds that disappear between products

Inefficient manufacturing isn’t always apparent. For instance, suppose an operator is spending 15 seconds arranging a part for 10 seconds, then another 10 seconds applying material, and then a few seconds transferring it to the next process. In the case of a single piece, the difference in time is not significant. When repeated a thousand times the second can increase production by a significant amount.

Wasted material is no different. This is also true for the waste material.

Companies that are thinking about robotic automation Australia will gain from looking at these small routine losses before they decide which equipment to buy. The needs analysis conducted by ASA is designed to uncover bottlenecks as well waste, quality issues and other process limitations that could affect an automation project.

Robots should be able to be integrated into the process.

Selecting a robot is only one decision in engineering. The system might also require guarding, tooling, controls, sensors fixtures, conveyors electronic integration, and connectivity with the existing production equipment. Engineers should consider reach and payload while also making decisions about how the robot can move around its work area and interact with the environment around it.

ASA offers conceptual development, design of systems and offline programming in its approach to robotic automation. Engineers can look at system configurations and estimate the number of cycles required before the system is finally installed in the factory floor. That becomes particularly useful when space is scarce or when new robotics need to be integrated with a production line that is already in place.

Painting and Dispensing Show Why Repetability is Important

Certain manufacturing processes highlight the value of controlled movement particularly well. Imagine applying a coat to hundreds of parts. It’s not enough to finish every component quickly. From the moment of starting production through the conclusion moving, speed and distance must be controlled.

ASA has specialists who work on painting and dispensing applications across a range of industries including automotive as well as aerospace. Industrial robotic automation in these environments allows for repeatable motions while limiting exposure of employees to physically demanding procedures or ones that may cause harm.

An improved control over the waste material can also increase productivity by decreasing the amount of unneeded material that is consumed.

Even after the installation it still needs individuals

Automatism isn’t a substitute for manufacturing knowledge. It alters the knowledge required to run and maintain the process.

Employees must be able to operate equipment in a safe manner identify abnormal behavior as well as troubleshoot issues and take care of maintenance. Systems and procedures are able to be changed later if production requirements shift.

ASA provides training on site including programming, safety troubleshooting, and mechanical and electric maintenance. It also offers servicing and support on a regular basis to assess the condition of equipment and to address wear and tear over the course of its operating life.

Capacity is more than Being able to work faster

For Australian producers, expanding capacity doesn’t necessarily mean buying a larger building or continually adding more workers to repetitive processes. The more important question to consider is whether the present manufacturing process can be improved.

ASA has been working on and integration of automation systems since 2002, supporting manufacturers in Australia and also projects internationally. Its methodology combines the analysis of requirements with engineering, simulations FANUC robotic integration and training and even servicing.

Automation isn’t the main goal. An investment-worthy system should offer a manufacturer measurable results, which include better production reliability, higher quality, safer processes and reduced waste, or an increase in capacity.