A manufacturing company wins a big contract. Production requirements for the month increase, but the factory does not suddenly gain flooring space, skilled workers or working hours during the daytime. A temporary increase in production is possible, but adding another shift can introduce new labor requirements as well as training, supervision, and quality control.

This situation highlights a major reason for robots. Robotics doesn’t just mean replacing humans with machines. In the right application it could alter the way companies use the capacity they have.

Image credit: automatedsolutions.com.au

Check out the time that passes between the products

Inefficient manufacturing is not always evident. Suppose an operator spends 15 seconds positioning a component for 10 seconds, then another 10 seconds applying material, and then a few seconds transferring it to the next operation. For one part it’s not much of a difference. These seconds add up when multiplied by thousands.

This is also true of wasted material. A small amount of extra coating or dispensing material multiplied across a high-volume production run 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 analysis of needs is designed to identify bottlenecks and quality issues as in addition to waste and other constraints during a project.

The robot must fit the process around it

Robots are just one of the many engineering choices. The system could also require tools, guarding devices, controls, conveyors, fixtures, electrical integration, and communication with the existing production equipment. Engineers should consider the robot’s reach and payload, and how it will interact with its surroundings and move around.

ASA provides concept development, system design, CAD simulation, and offline programming as part of its strategy to FANUC’s robotic automation. The digital simulation allows engineers to analyze configurations, estimate cycles times, and evaluate the system prior to it becoming operational on the customer’s floor. This is particularly beneficial when space is scarce or new robotics must integrate with an established production line.

The importance of consistency in painting and dispensing

The ability to control movement is particularly important in certain manufacturing processes. Imagine covering hundreds of components. The desired result isn’t merely the process of completing every component in a short time. From the moment of starting production through the conclusion all the movements, speed, distance and application must be managed.

The experts at ASA are proficient in painting and dispensing across different industries such as aerospace and automotive. In these settings, industrial robotic automation can provide the ability to repeat, programmed, and controlled movements. It also decreases the risk of exposure for employees to potentially dangerous processes.

Improved control can also cut down on excessive material consumption, thereby contributing to a reduction in waste and productivity enhancements.

Installing the system is not enough. It is still necessary to have people to keep it running.

Automation is not a complete solution to the need for manufacturing expertise. Automation can alter the capabilities needed to operate and maintain the process.

Employees should be able to detect abnormal behavior and identify problems, as well as perform the appropriate maintenance. Production requirements can also alter, indicating that the processes and programs could require adjustments later on.

ASA provides training on-site for safe operation, programming troubleshooting, as well as electrical and mechanical maintenance. The company provides ongoing maintenance and services to ensure that equipment is in top working order and wear and tear issues are addressed.

Capacity is greater than working faster

In Australia, boosting production capacity doesn’t always mean adding more employees to repetitive jobs or buying larger structures. Sometimes, the best question is whether or not the existing manufacturing process could be designed differently.

ASA has been designing and the integration of automation solutions since 2002. It provides support to manufacturers in Australia as well as international projects. Its approach combines needs analysis, engineering simulation, FANUC integration as well as training and maintenance.

Automation is not the only goal. A worthwhile system should give an industry a tangible terms of increased reliability and quality, as well as safer procedures, less waste or more capacity from the factory that it currently operates.