Concentrating on the wrong drivers for automation is a major error but one that we sadly see all too frequently .
materials , joining techniques and production methods which won ’ t all necessarily work together to produce something that is easily automated , but which designers are reluctant to give up . However , it can be better to take a hit on one material or process to make things easier to automate , thereby reducing overall production costs .
2 . Prioritise parts
Focus on part delivery methods within the complete solution . Often , customers will come to us looking for an automated solution , but with their component parts delivered in no ordered way . As much as 20-30 % of the cost of the project can be spent on getting those parts located or fixtured and ready to process before the real automation process can actually begin . It makes more commercial sense to keep parts in order , whether that ’ s in a nested box , on a conveyor or in a stack .
Also think about part handling and fixturing . Significant costs could end up being channelled into part fixturing – even more so if you are working with a range of parts due to multiple fixtures . A good example of best practice here is to focus on one-way assembly ; for example , where parts stack on top of each other to create the complete product or common part features that allow common fixturing .
3 . Consider TCO
Concentrating on the wrong drivers for automation is a major error but one that we sadly see all too frequently . Some customers are more focused on fitting an automation solution into a defined payback period ( often under two years ) instead of looking at the value it will bring to the business over its lifetime . A total cost of ownership model is a far better measure . Purchase price only accounts for between 15-25 % of the total cost of ownership ; the remainder is made up of factors such as maintenance , energy usage , repairs , and even end of life . Measuring TCO rather than ROI will ensure you get the right automation solution for your business , resulting in real longterm value .
4 . Remember the process , not just the consumer
It can be tempting when developing a new product to prioritise what ’ s easiest for the consumer , without realising that this may negatively impact the automation process . A prime example of this is shelf-ready packaging . The current trend within food manufacturing for front-facing packaging with tearoff flaps or loose fitting lids allows retailers quick and easy restocking of shelves . However , this seemingly simple change in packaging design has made it extremely difficult for automation to be exploited for end-of-line palletising , as the loose fitting lid or tear-off flap is not conducive to staying in place . Therefore , before making any packaging changes – no matter how seemingly minor – think carefully about how they may impact your ability to automate , and the effect this will have on production efficiency and labour demand .
5 . Talk to automation suppliers
Engage with automation suppliers as early as possible . At FANUC , we are more than happy to support designers that are beginning their journey towards automation and will readily provide guidance on what the process is going to involve . We ’ ve done this countless times throughout the years as different sectors have started to embrace automation – from manufacturers of low-cost products to high-value goods ; companies in the food industry ; and more recently , with EV battery manufacturing for the automotive sector . We have rounded experience across lots of different applications within a wide range of industries that we are happy to share , and which designers can learn from .
6 . Try before you buy Finally , as in many industries , some automation suppliers are now starting to offer low-cost / low-risk routes into automation for companies taking their first steps into automation . Robots as a Service ( RaaS ) is a subscriptionbased option that enables manufacturers to pay a set fee over a specified period of time , and effectively lease a robot to use in their facility . The limitation of this offering is that it will only suit certain simple applications , for example , palletising , or particular welding options . The upside is that the robot can be repurposed for multiple product types – palletising a box of cakes is effectively the same process as palletising a box of dishwasher tables , for instance . Talk to your automation supplier to determine if RaaS could be right for your needs in the short-term – by allowing firms to test the water and experience the benefits before making their own investment , it can represent an affordable route into automation for some firsttime users .
In conclusion , when designing or upgrading any production line , make sure to consider automation as one of the cornerstones of your project from the outset . By working with a reputable automation supplier , you can ensure your manufacturing facility is optimised for success , not just for today , but for years to come .
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