Small and medium-sized manufacturers (SMMs) often invest in automation, such as collaborative robots (cobots), after seeing their capabilities demonstrated. However, without fully considering how this technology will impact their workforce and processes, successful implementation is less likely. The key to a successful first automation project is clearly defining the problem that needs solving. Whether addressing labor shortages or process inefficiencies, understanding the specific issue the automation is intended to resolve is crucial for achieving desired outcomes and maximizing the return on investment.

Once you have decided what to take on with your next automation project, these two approaches can help improve your chances for success:

• Link the initiative to financial performance. Automation and Industry 4.0 provide the connectivity and access that can make your operations more data driven. Better data provides a window into your operations, enabling you to realize the amount of money you are making or losing in real time.
• Use a system mindset for adoption. With clear goals in mind, build a system around the technology. For example, while a cobot is great at replicating a repetitive motion, it needs to be programmed for each separate task you want it to perform. Think about providing your team with human-machine interface (HMI) training to introduce them to automation controls. This is especially important for high-mix, low-volume operations.

Have a Plan Before Getting a Quote

When requesting quotes from technology vendors and automation integrators, it's possible to receive a "no quote" if the project doesn't meet their minimum revenue threshold or if it's deemed too risky. If quoted, the investment might be larger than anticipated. It's important to decide between starting with hard automation (physical equipment) or soft automation (software for data collection and monitoring). For many small or medium-sized manufacturers, utilizing a Manufacturing Execution System (MES) is a productive initial step.

To help your decision-making process, start by making a process map of your operations to confirm what causes variations and issues. This will help determine what types of tools or automation may be in order. How do you know if a process can be handled by a collaborative robot or an industrial robot? Consider the following:

• Cobots are designed for safe human interaction, generally operate at slower speeds, and have lower payload capabilities. Ideal cobot applications include:
  • Loading or moving lightweight boxes
  • Bin picking with a gripper
  • Tape dispensing and similar repetitive motions
  • Machine tending
• Industrial robots typically offer higher speed and payload capacities, making them suitable for heavy-duty operations, such as:
  • A dangerous welding application
  • Painting that emits hazardous chemicals
  • Lifting heavy bags

Outline Your Process: Final Stage Palletizing

Once you determine what you want to accomplish with your automation project, it's time to map out a process to scope the requirements. Consider end-of-line palletizing as a prime candidate for automation. It's a repetitive task often avoided by workers, leading to frequent vacancies. Automating this process can provide a straightforward return on investment (ROI). Here's how a typical process might unfold:

1. First, identify the requirements, such as picking a box from a conveyor, moving it above a pallet, and placing it on the pallet.
2. Then identify the sources of variation, such as the box size and condition, conveyer position, pallet height and position, and the box arrangement on the pallet, etc.
3. Next, identify the solution that meets your needs, such as what type of cobot or robot to use, the type of arm tool, mounting, and machine integration requirements.

Consider mounting as an example. Since robots require space to operate efficiently, avoid placing the base of a robotic arm directly above or below where it will grab parts. There are also various mounting options for a robot. If using a cart for flexibility, ensure you have calibration fixtures or vision systems in place to maintain the robot's correct position and orientation for the task.

Begin Slowly with a Systematic Approach to Ensure Success and Return on Investment

The best automation projects involve structuring a process that combine work tasks with multiple facets of your operation. It's part of a big-picture transition that provides more paths forward and more impactful ROI. A "one-off" or isolated task has limited impact and is less likely to succeed.

It's crucial to set up for success, even if it requires a slower pace. For instance, building a system or process for the first time might take several months. However, if done correctly, the investment can often pay off within six months. Two key factors influence this outcome:

1. Once the system and processes are ready, you often can get a robot running in a couple of days.
2. Automation vendors may not teach you how to build a system. Their goal is to get the application online as quickly as possible.

It's important to incorporate any automation application into your system so your people on the floor will know how to respond if a machine is down or operating at less than peak efficiency. Many automation implementation projects struggle when no one pays attention to a dashboard that is "in the red," (indicating ongoing issues), as they do not feel empowered to take actions.

That's why it's important to consider your team's skills and abilities when planning for the implementation, operation, and support of automation.

• Who is going to build, install, and integrate the system? Are you going to do it in-house or hire an integrator?
• Who teaches your operators? You can program motion, but can your robot talk to tooling, grippers, etc.? Do you need to bring these automation skills in-house?
• It's also crucial to plan for long-term support of the automation, ensuring that you have the necessary resources in place so you don't become overly reliant on external vendors.

How Manufacture Nevada Can Help

Small and medium-sized manufacturers often recognize the need to invest in automation, but without a clear plan and understanding of its impact on people and processes these efforts can fall short. Manufacture Nevada offers the expertise needed to navigate these challenges successfully. By working with Manufacture Nevada, small and medium-sized manufacturers can identify the right automation solutions tailored to their specific needs, ensuring a strong return on investment (ROI). Manufacture Nevada can assist with everything from initial assessments to long-term support, helping manufacturers optimize their operations and improve financial performance.

Reach out to our Business Advisors today for a consultation.

Content from this blog was sourced from Michigan Manufacturing Technology Center.