Operational adversity is inevitable in manufacturing, there will always be setbacks and periods of difficulty. But meeting adversity with diversity in the way that we approach our operational processes, is key to future-proofing our operations.
Every manufacturing business should have a contingency plan and, within that plan should feature robotics and automation. We don’t know what is around the corner and, in order that we can continue to operate whatever the challenge that we might be faced with, is imperative. Consider changes and fluctuations in market trends, issues with sourcing affordable manual labour or other factors that can complicate manufacturing capability.
Whilst many large manufacturing organizations have been using automation as standard within their supply chain, as a value-add concept to some SME’s and start-ups, it is a solution that can appear to be beyond their reach. Whether from a financial outlay perspective or, they are not able to envisage an automated application within their operational infrastructure.
But when faced with the slowdown or suspension of operations due to circumstances beyond their control, managing business interruption by way of established automated robotic applications can be the difference between continuing to operate, even at reduced output than not at all.
The question is, however, where do you see that value can be afforded through the implementation of robotics? Automating for the sake of automating is not a cost-effective exercise unless you have properly analysed your workflow and defined your goal for automating, which could be one of many outcomes. Do you want to increase productivity; improve upon product quality; is the exercise one that should deliver cost savings; do you want to upskill your workforce?
This last point is an emotive one in that, there is a misconception that robotics and automation threaten jobs. The simple fact is that they don’t. Operators become robot programmers, improvements in operational processes lead to an increase in product output, thus the operational logistics of a business must be sufficiently staffed, aligned with production growth. It is also worth noting that there are robots that have been designed to work alongside humans, in collaborative manufacturing scenarios.
So, where does automation add value? The simple way to identify the areas within an operation is to walk along your production line. Robots can be adopted to undertake any number of repetitive tasks; machining, inspection, surface treatment, maintenance/repair, loading and unloading. The list is endless, though determining just where such investment shall provide a return is key.
Where might the most downtime be recorded; what has caused this; what impact is this having upon your operational performance; how effective is your technology, it’s OEE (overall equipment effectiveness); what costs are associated with maintenance; what are the impacts upon your revenues associated with any underlying causes? Operational analysis is the only way that you shall determine the criticality of any of the criteria you might explore.
Most leading robot manufacturers will work with an established portfolio of industry-renowned system partners or integrators, who specialise in the design of robotic applications, specific to your industry, from solution realisation (can it be achieved) to installation. What might not seem like an obvious fit for automation in your eyes, will make perfect operational sense to them. There are also means by which you can envisage just what your automated environment will look like, without a robot even setting foot inside your facility. These are called digital twins and, are essentially a virtual representation of your physical system. A virtual model that is the exact ‘twin’ can be presented by way of a three-dimensional CAD simulation or, in virtual or augmented reality. This digital representation provides both the characteristics and dynamics associated with your automated solution.
So, now you have a business case for robotic process automation there is the cost consideration. Automated robotics doesn’t have to cost the earth, careful analysis (as detailed above) will ensure that any investment you make shall deliver returns. Adopting automation can cost a fraction of what it costs to sustain a manual labour force. After all, they can operate 24/7 without the need to take breaks, go on holiday, take time away from the factory floor due to sickness. The biggest cost is the initial investment, but again, there are ways and means of acquiring the robotic equipment needed.
There are some robot manufacturers that offer leasing opportunities that enable you to acquire robotic technology, the perfect financial solution for some SME’s or even start-up’s that might not have the cash flow to justify a large investment in capital equipment. Catapult centres, a national manufacturing and research institutions are also on hand, supporting manufacturers to make the transition from manual, to fully autonomous processes.
By adopting automated robotic processes, you as a business, are empowered to become more competitive, improve your product quality and, increase production yield and, the steps to achieving automated excellence are not as complicated as you may think. With the right industry partner on board to provide the right guidance and, identify your value-add areas, so you can reap the benefits that can be obtained by using robotic process automation.
