ACE Issue 31 2022 | Page 23

Since the days of factory pioneer Henry Ford , manufacturing plants have worked in a similar way — with long , linear production lines where items pass from station to station , being processed and finally inspected and shipped . In these lines , every change requires the intervention of multiple experts and can lead to several weeks of expensive downtime .
On the other hand , automation cells allow for a modular and easily scalable factory structure . These cells can be quickly rearranged on the factory floor whenever manufacturers need to restructure the production process — some models even come on wheels .
Another great advantage of automation cells is that they can be placed in any building where there is enough floor space . This means facilities like empty warehouses can be easily repurposed to set up a new production plant in record times .
This approach is perfect for manufacturers that need to establish a new production line very quickly , for example to respond to a sudden surge in demand . However , it will also facilitate those who are planning to bring production closer to the final customer to save on logistics costs , reduce lead time and minimise the company ’ s overall carbon footprint .
Compared to traditional production lines , automation cells offer unprecedented flexibility .
For example , British electric vehicles ( EVs ) start-up Arrival uses flexible automation cells in its microfactories , which are small-scale production plants that the company is planning to set up on the outskirts of cities worldwide . The use of automation cells allows the company to set up new production lines very quickly , so instead of relying on production sites overseas , Arrival has chosen this innovative approach to reduce costs by bringing production closer to where its vehicles are needed .
A further advantage of automation cells is that a factory structured this way can be very easily scaled up and down according to market demand , by simply adding or subtracting cells . This is a great approach for start-ups and smaller manufacturing companies who might not be in the position to invest in a huge and cost-prohibitive facility but want to give themselves space to grow .
A LOOK WITHIN — STANDARD COMPONENTS The beauty of automation cells is that they contain everything the plant needs to automate the production process — or at least some of its core aspects — in an extremely compact architecture . Like Lego building blocks , the components in the cells are structured so that they all fit together to occupy the least possible space .
This is leading to an interesting phenomenon in equipment manufacturing — the standardisation of automation machinery . Traditionally , production and assembly lines were bespoke projects that required the expertise of several high-skilled professionals , such as design engineers and systems integrators . Designing , building and testing the line took several months , was extremely expensive , and required long periods of downtime .
On the other hand , automation cells can be realised in less than one week , although up to three weeks may be needed to map out the necessary tasks within the cell and establish the optimal workflow . There are even useful digital tools to help users in the process . For example , FANUC ’ s Build Your Cell configurator guides users at every step to create the ideal cell for their application .
The benefits of automation cells are clear — production can start shortly after the manufacturer perceives the need for new workstations , either because of unprecedented demand , or because of the necessity to adapt production to new specifications . As well as this , costs are minimised and the overall agility of the plant is increased .
It seems clear that manufacturing is evolving from an industry based on cumbersome , bespoke projects to one that requires extreme flexibility through the use of modular architectures and standardised components . Automation cells offer a great chance to innovate manufacturers ’ business models and keep up with the ever-evolving needs of an increasingly demanding global market .
For weekly updates on the new trends in smart manufacturing , and to order a wide variety of quality automation components from all major brands , visit www . euautomation . com .
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