Automated Manufacturing – Help your Robotic Project SucceedIndustrial AutomationAutomated ManufacturingAutomated Manufacturing AdviceTips on Automated ManufacturingAutomation – A Guide for Small BusinessesAn Idiot’s Guide to Automation
Investing in robotic equipment can be a big leap for a small business, especially since such a move would have been unthinkable only a few decades ago. Industrial robots have been automating tasks since 1961. The first industrial robot, named the Unimate, worked with the die casting machines at a General Motors factory. In the last decade there has been a surge of robots being integrated into mid-sized and smaller companies. One reason is the growth and affordability of the used robot market. With new technologies becoming available, companies are upgrading robots before the current model has finished its life-span. However, the overall functionality of the six-axis articulated arm hasn’t changed in the last decade. As organizations consolidate and reorganize, older robots are sold. The many benefits of automation include saving money and reducing production time. Automation can also lead to an increase in part quality and reliability.
These are some hints to help you make the leap to automated manufacturing.
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Get Advice from the Workers
It’s always a good idea to talk with your workers before you implement any changes. These people know that specific phase of the manufacturing process best of all, and their input can be invaluable. They sometimes have helpful insights into the manufacturing process that you can not gain by simply watching.
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The people who manually perform the process can advise you on the configuration and specifications of the equipment up front, avoiding the possibility that the equipment is not as ergonomically friendly or productive as it could be. Failure to involve these people would be a waste of their valuable knowledge and experience.
Carefully Choose Your Robot Operators
Most industrial robots are controlled by the use of teach pendants. Several of these pendants are now programmed with an interface that resembles a personal computer. A computer literate individual should have no trouble learning how to instruct the robot and moving it to complete the desired tasks, such as welding or material handling. The challenge training a welding robot how to perform a specific welding task is best handled by somebody with manual welding experience. This would be an ideal person to choose for the job of programming or operating your robotic welder. When choosing robot programmers, operators, and technicians, special consideration should be given to motivated personnel that are prepared to learn and advance their skills.
Learning to Operate your Robots
There’s no point buying a robot if you do not know how it works, so be sure you buy a control system that delivers adequate training. This will allow you to better utilize your robot and minimize down time by making it easier to address technical issues down the road. . If given adequate instruction, the programmer should be able to reliably generate an effective robot program. Basic groundwork training is a minimum, the real education will take place on the shop floor.
Your robotic integrator will normally program your robotic system to interact with your current equipment and create a turnkey solution that requires only a push of a button. No matter how straightforward the system is, it is still neccessary to have trained personnel on site to monitor and maintain your apparatus. Routine maintenance, such as annual grease replenishment and battery replacement, is also an issue that you will want a trained individual to perform. Many robotic systems have been destroyed by well-meaning maintenance by individuals that do not understand the complexities of the robotic system.
Watch for Repeatability
The biggest problem with robotic welders is part quality. Robotic systems are designed to perform specific tasks repeatedly. If the robot has been damaged, repeatability can become an issue. For example, if the robot makes a mistake, it will repeat that mistake over and over. However, when a robot is correctly programmed and functioning correctly, it’s reliability cannot be matched.
Seam tracking and touch sensing can be utilized to compensate for weld joints that are not static, however robots are still limited by the laws of physics. The use of high quality apparatus along with manufacturing robots improves the part fit-up. Be sure to pay attention to welding and cutting torches, lasers, raw consumables, and pieces of equipment that might lead to a loss of quality.
Estimate Your Rate of Return
There has been a steady growth in the number of robots being used in the manufacturing industry over the last few years. Experts forecast that this growth will continue for atleast the next decade. Welding robots are still the majority of the market, but many applications can be handled by robots. The basic rule-of-thumb is that a robot welder can do the work of four human welders. The cost effectiveness of these machines makes the switch to automated manufacturing easily justified. It can also lead to increased efficiency, higher part quality and increased productivity.
