The first step to automating your production line
Regardless of which system you choose, all of your new automation creative ideas should work within your organizational context and budget.
Other countries, as well as your competitors, are adopting new automation technologies that allow them to be more competitive. See automation concepts as an opportunity to keep yourself and your company relevant.
You won't know if you have a knack for automation until you start planning. Initial planning is as easy as determining if your production line will be more efficient as a stationary, programmable, or flexible design.
Before you get started, talk to your IT department about interoperability and software and hardware from the Internet of Things (IoT), start by looking at your current production floor setup your and think like a machine designer. Check the efficiency of your current system and look for bottlenecks. Encourage employees to share experiences and ideas to improve production line processes. People on the front lines can provide a wealth of creative ideas to effectively create automation. Once you have an idea of the production areas that need the most improvement, then you can start thinking about machines.
For optimal profit margin on machine cost, a designer needs to know the following before he can design automation:
- Is the product produced in units, batches, continuous or in bulk?
- Will the workstations operate synchronously or asynchronously?
- What is the total number of workstations needed?
- What is the available production space? This will decide the machine layout, linear indexing.
Once these questions are answered, the design of the machine falls into one of three categories:
1 - Fixed or hard automation
Fixed automation equipment produces large volumes of the same product day in and day out. Having a fixed sequence of activities does not require customization. Operations are directed by the layout of machines and components.
Advantage:
Typically, a stationary system is a lower cost option when compared to flexible and programmable machine builders.
- Fixed automation provides improved product quality through consistency.
- Fixed equipment works with fixed high speed which increases production speed.
- When using stationary equipment, ROI is positive due to lower unit cost per unit sold.
Defect:
- The fixed machine layout is not flexible, so the design change is very expensive and time consuming.
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2 - Programmable automation
Programmable automation is for the manufacturer that requires a flexible production line to run in batches. This system allows machine reconfiguration or reprogramming to different product specifications. Computer numerical control (CNC) automates the control of machines through software and is an example of programmable automation.
Advantage:
- The system is more flexible than fixed, thus providing for several product variables.
- This system is designed to run several dozen to over 1000 units.
Defect:
- For product variables, reconfiguring system and device software can still be time consuming.
- With a programmable device, the upfront cost is higher than with a general-purpose machine.
3 - Flexible or soft automation
An extension of programmable automation, this system allows for even greater flexibility in running batches with less down time. With this system, you will often see cobots and robotic arms with different types of grips.
Advantage:
- Small batches can be generated with minimal machine downtime.
- Continuous production is enhanced by adjusting the programmed product variables in sequence.
Defect:
- This system requires the most upfront investment.
- Components must be incorporated to allow for rapid changes, such as robotic arms that require logic controllers, sensors, and lasers.
Skilled labor will be needed for parts change, programming and maintenance.
Regardless of which system you choose, all of your new automation creative ideas should work within your organizational context and budget. But your planning is not in vain. You've calculated the benefits of automating your production line and are ready to start implementing the changes. Automation doesn't have to be everything, it can start in steps.
If you're just starting to grasp concepts from the IoT, don't feel like you have to start with a giant machine update. Narrowing your needs and starting slow puts development and testing under control. This will also give you time to absorb and digest new manufacturing technologies. You might be surprised at how quickly you catch up.
Related Posts:
You won't know if you have a knack for automation until you start planning. Initial planning is as easy as determining if your production line will be more efficient as a stationary, programmable, or flexible design.
Before you get started, talk to your IT department about interoperability and software and hardware from the Internet of Things (IoT), start by looking at your current production floor setup your and think like a machine designer. Check the efficiency of your current system and look for bottlenecks. Encourage employees to share experiences and ideas to improve production line processes. People on the front lines can provide a wealth of creative ideas to effectively create automation. Once you have an idea of the production areas that need the most improvement, then you can start thinking about machines.
For optimal profit margin on machine cost, a designer needs to know the following before he can design automation:
- Is the product produced in units, batches, continuous or in bulk?
- Will the workstations operate synchronously or asynchronously?
- What is the total number of workstations needed?
- What is the available production space? This will decide the machine layout, linear indexing.
Once these questions are answered, the design of the machine falls into one of three categories:
1 - Fixed or hard automation
Fixed automation equipment produces large volumes of the same product day in and day out. Having a fixed sequence of activities does not require customization. Operations are directed by the layout of machines and components.
Advantage:
Typically, a stationary system is a lower cost option when compared to flexible and programmable machine builders.
- Fixed automation provides improved product quality through consistency.
- Fixed equipment works with fixed high speed which increases production speed.
- When using stationary equipment, ROI is positive due to lower unit cost per unit sold.
Defect:
- The fixed machine layout is not flexible, so the design change is very expensive and time consuming.
2 - Programmable automation
Programmable automation is for the manufacturer that requires a flexible production line to run in batches. This system allows machine reconfiguration or reprogramming to different product specifications. Computer numerical control (CNC) automates the control of machines through software and is an example of programmable automation.
Advantage:
- The system is more flexible than fixed, thus providing for several product variables.
- This system is designed to run several dozen to over 1000 units.
Defect:
- For product variables, reconfiguring system and device software can still be time consuming.
- With a programmable device, the upfront cost is higher than with a general-purpose machine.
3 - Flexible or soft automation
An extension of programmable automation, this system allows for even greater flexibility in running batches with less down time. With this system, you will often see cobots and robotic arms with different types of grips.
Advantage:
- Small batches can be generated with minimal machine downtime.
- Continuous production is enhanced by adjusting the programmed product variables in sequence.
Defect:
- This system requires the most upfront investment.
- Components must be incorporated to allow for rapid changes, such as robotic arms that require logic controllers, sensors, and lasers.
Skilled labor will be needed for parts change, programming and maintenance.
Epilogue
Regardless of which system you choose, all of your new automation creative ideas should work within your organizational context and budget. But your planning is not in vain. You've calculated the benefits of automating your production line and are ready to start implementing the changes. Automation doesn't have to be everything, it can start in steps.
If you're just starting to grasp concepts from the IoT, don't feel like you have to start with a giant machine update. Narrowing your needs and starting slow puts development and testing under control. This will also give you time to absorb and digest new manufacturing technologies. You might be surprised at how quickly you catch up.
Related Posts:
- Outstanding advantages of gravity roller conveyor system
- The benefits of automatic sorting systems in today"s warehouses
- Advantages and disadvantages of automation in production
