The Production Bottleneck Nobody Notices Until Customer Orders Increase

A significant contract is won by an industrial manufacturer. The monthly production demands increase, yet the factory hasn’t seen a sudden increase in floor space, experienced employees or even hours per daytime. While adding another shift may temporarily boost production, it could be a source of new work, supervision, training and the need for quality control.

Situations like this reveal an important function of robotic automation. Robotics isn’t only about replacing human beings with machines. A suitable application can alter how manufacturers use their capacity to produce.

Image credit: automatedsolutions.com.au

Take a look at the time intervals between the products

Inefficiency in manufacturing doesn’t have to be dramatic. An operator may spend 15 minutes positioning the item, then 10 seconds applying materials, and a couple of seconds moving it onto the next stage. The difference may seem insignificant for one component. If repeated thousands of times, these seconds can turn into significant production time.

It’s the same with wasted material. The same is true for waste material.

Companies looking into robotic automation Australia projects can gain from examining these minor frequent losses prior to deciding what equipment they need. The analysis provided by ASA is designed to identify bottlenecks and quality issues as in addition to additional constraints and waste within a project.

The robot has to fit the system around it.

The choice of a robot is just one engineering decision. It is possible to install tooling, protection and controls sensors, conveyers, fixtures, electronic integration, and communications with the current production equipment. Engineers must take into consideration reach and payload when determining how the robot will move through its area of work and interact with the environment surrounding it.

ASA provides concept development, system design, CAD simulation, and offline programming as part of its approach to FANUC robotic automation. Engineers are able to explore configurations for the system and estimate cycle times before the system is finally installed on the floor of the factory. This is especially useful when space is constrained or new robotics must integrate into an existing production line.

Painting and dispensing show why It’s Important to Repeat

Certain manufacturing processes show the importance of controlled movements. Imagine coating hundreds of parts. It’s not enough to finish each part quickly. From the beginning of production through the conclusion the speed, movement and distance must be managed.

ASA’s specialists are experienced in painting and dispensing across industries including aerospace and automotive. Industrial robotic automation in these industries allows for reproducible movements and reduce the risk of workers to physical demands or processes that could be dangerous.

A better control of waste materials can also contribute to productivity improvements by cutting down on the amount of waste material that is consumed.

The System Still Needs Personnel After Installation

Automation doesn’t eliminate the need for expertise in manufacturing. It transforms the knowledge needed to run and maintain the manufacturing process.

Employees must be taught to safely use equipment, identify abnormal behavior as well as troubleshoot components that are malfunctioning and perform necessary maintenance. Processes and programs can be changed later in the event that the production needs are changed.

ASA offers training on site that covers programming, safety troubleshooting, mechanical and electric maintenance. The company offers servicing and support for checking the condition of equipment, and dealing with wear and tear throughout the life of the system.

Capacity is more than just working more quickly

An increase in capacity for Australian manufacturing companies doesn’t mean buying a bigger building or adding more labor to repeat processes. Sometimes the better question is whether or not the existing manufacturing process can be designed differently.

ASA has been creating and integrated automation systems since 2002. It has assisted companies in Australia and projects internationally. Its method combines analysis of needs, engineering, simulations, FANUC robotic integration, training, and also servicing.

The objective isn’t automation just for the sake of automation. A successful system must give a manufacturer something measurable in yield, more stable production that is consistent in quality, more secure procedures, less waste or more capacity from the factory it already operates.