Seven Steps to a Successful Robotic Automation Project
Successful automation takes good planning and working knowledge of your company’s production process. It requires an understanding of robotics – its benefits and limitations, and an employee and management buy-in. In the end, the rewards are worth the time and investment. A successful automation project will optimize your manufacturing processes, lower costs, improve quality, minimize waste, and provide a safer work environment.
1. Find a good integrator.
Finding a reliable dealer/integrator is the single most important decision a new buyer must make. If you choose wisely, this company will support your automation throughout the installation, maintenance, and service life of your robot. Choose a reputable company with knowledgeable service technicians, customer-oriented management, and qualified references.
2. Create a workable plan.
• Feasibility study: Determine if robotics is feasible for your application. You and your team must be knowledgeable about your production process from the moment material or components enter the production floor to the time the end product is sent out for distribution. This information must be communicated to your integrator.
• Return on Investment: The bottom line for you and for your company is payback. “Return on Investment” should be in the two to three year range for a new robot. Pre-owned robots will have more immediate results in return on your investment. When calculating ROI for Robotics, examine the potential for increased productivity, fewer defects, fewer work slippages and reduced worker compensation claims. On the other side of the equation consider the cost of the robotic system, tooling, and training.
3. Have reasonable expectations
• Understand the limitations of robotics automation: Every robotic automation project is based on robot features: payload, repeatability, speed, and work envelope. Over-estimating or under-estimating any of the features will cause problems with the end result.
• Keep it Simple! Resist over-engineering. A good design is one that’s reliable, straightforward to use, and easy to repair and maintain. Don’t ask the robot to do more than it is capable of doing.
• Flexibility: Whenever possible, automation should be designed with as much flexibility as possible to allow for future or alternative applications.
4. Management and employee buy-in: This point cannot be emphasized enough! Change is never easy. If management is not willing to support automation on an ongoing basis, more than likely the project will fizzle. As soon as a problem arises, they will turn of the project and scrap the automation. Likewise, if employees consider automation to be a threat to their job, or if they have a fear of new technology, they will sabotage the automation project, overtly or subliminally.
5. Understand the total cost of putting a robot into production.
• Training: Take advantage of training offered by a good integrator. It will save money in the life of the robot.
• Tooling: End-of-Arm Tooling or End-Effectors are grippers, cutters, welders, grinders, and a number of other tools that perform the function for the robot. It is important to have good tooling backed up by your integrator. This is usually a separate line item.
• Integration with current manufacturing process: Either your integrator or your employees must make your automation system work with your manufacturing process. This could require additional time and material.
6. Supply consistent parts and fixtures:
Because of the repeatability aspect of robotics, parts and fixtures must be more consistent than they might be with a manual line. Repeatability is the ability of a robot to return to the same position over and over again. This repeated movement is measured over a period of time. If the parts or fixtures are not consistent, the robot will not be able to perform its programmed task accurately.
7. Use the resources of your integrator:
Once again, a good integrator is the key to successful automation. A quality integrator will help you with all the steps above, making the installation seamless and the automation successful.
KC Robotics has over twenty years experience in automation and industrial robotics. Our technicians and project engineers consult with the customer to determine the correct robot, tooling, and integration needs for the automation project. We pride ourselves in customer support throughout the project.
