A manufacturing company wins a big contract. Production requirements for the month increase, yet the factory isn’t gaining flooring space, skilled workers or working hours during the day. An increase in production for a short period could be possible, however the addition of a shift could introduce new requirements for labor, training, supervision and quality control.

This situation reveals a key need for robotic automation. It’s not just about replacing people with an automated machine. When used in the right way, it can change how companies use the capacity they already have.

Image credit: automatedsolutions.com.au

Check out the seconds between products

Inefficient manufacturing is not always apparent. For instance, suppose an operator is spending 15 seconds arranging a part for 10 seconds, then another 10 seconds applying the material, and a few seconds transferring it to the next process. On one piece it’s not much of a difference. These seconds add up when multiplied by thousands.

This is also true of wasted material. The addition of a tiny amount of additional coating or dispensing materials throughout a massive production line can lead to an enormous expense.

Before choosing the equipment they require, businesses looking into robotic automation Australia could benefit from analyzing these small losses. ASA’s analysis of requirements is designed to identify problems with quality and bottlenecks as also additional constraints and waste in a project.

The robot must fit the process around it

The decision to choose a robot represents only one decision in engineering. It is possible to incorporate tooling, security and controls sensors, conveyers, fixtures, electrical integration and communication with the existing production equipment. Engineers must take into consideration the robot’s reach and payload as well as how it will interact with its surroundings and move about.

ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. The digital simulation allows engineers examine configurations, estimate cycle time and allow them to test the system prior to it becoming in operation on the floor of the customer’s. It’s particularly useful in situations where there is a restricted amount of space, or when the new robotics requires integration with the production line.

Painting and Dispensing Show Why It’s Important to Repeat

Certain manufacturing processes illustrate the importance of controlled movements. Imagine applying a coat to hundreds of components. It’s not enough to complete each piece quickly. The movement, distance, speed, and application have be managed from the beginning of the production run to the point of completion.

ASA has experts who deal in the field of dispensing and painting across all industries, including aeronautics and automobile. Industrial robotic automation in these environments allows for repeatable motions while reducing the exposure of workers to physically demanding procedures or processes that could be dangerous.

A better control system can also help reduce the amount of material used, which can lead to less waste, as well as productivity gains.

Even after the installation the system will still require users

Automatism isn’t a substitute for manufacturing knowledge. The skills required to operate, maintain and manage the process are changing.

Employees need to be able recognize unusual behavior and resolve issues, and carry out the correct maintenance. Processes and programs are able to be changed later if production requirements are changed.

ASA offers on-site training in safe operation, programming troubleshooting, and mechanical and electrical maintenance. The company also provides servicing and ongoing support to monitor the condition of equipment and address wear and tear over the course of its operating time.

Capacity is greater than working more quickly

In Australia, boosting production capacity does not always mean adding workers to repetitive tasks or purchasing bigger structures. Sometimes, it is better to ask if the production process can be modified.

ASA has been working on and integrating automation solutions in Australia since 2002. We also help with projects across the world. Its strategy combines analysis of needs along with engineering simulation FANUC integration along with training and servicing.

Automation isn’t a goal. A system that is worthy of the gold it’s worth will be able to provide tangible benefits for an enterprise, including more reliable production, better quality, safer processes and less waste.