There is no doubt that the vast majority of repeating processes in business have some level of automation. Something as simple as mailing labels for outgoing packages or using conveyor belts to move product from one place to another are concepts that have been in play for decades. As we continue to face labour challenges and look to the future of a rapidly evolving workforce, the need to streamline operations is more important than ever before. In this month's blog article, we're getting the thought-train chugging with some fresh automation ideas that we hope garner new conversations around process improvement possibilities in your business.
Pick and Place Applications
Conveyors have been in use for over 230 years, with early flour mill designs including a hand-operated crank and a leather belt running over a flat timber bed. Conceptually, nothing has changed but the next generation of manufacturing is now looking at the way product is moved to and from the conveyor.
In food manufacturing, a packed product, let's say plastic milk bottles after filling, capping and labelling, would need to be moved from a conveyor to a milk crate. Being a reasonably heavy item, the use of a clamp/gripper type component would best suit the task. The PHD GRW series have a versatile gripper mounting system that allows for a custom solution to be designed to pick up the bottles in such a way that their balance is maintained and they can be loaded effectively in to a milk crate. A series of actuators and sensors would then be used to locate the milk crate and lower the filled bottles into the crate. Along the way, there are often requirements to eliminate static which can be done using our range of static elimination equipment from Fraser.
The take away, ask yourself what processes could benefit from product being automatically 'moved' from one location to another, rather than having a person do the task?
Hold Down Clamps for Welding
Traditional methods often rely on manual clamping or fixtures, which can be time-consuming and prone to human error.
As an example, a fence and gate manufacturing business could increase accuracy, productivity and overall quality by utilising a PHD Series PB Versatile Swing Clamp. This unit can hold down the product components in their exact template locations and then swing out of the way for part loading, they can also be optioned with weld covers for additional rod protection leading to longer service life. This precise component placement would then allow the operator to focus exclusively on quality welds, significantly helping to reduce setup time and material wastage from human error.
The reality is, the integration of automation is no longer just an upgrade, it’s a competitive necessity in today’s manufacturing industries.
The take away; what time could be saved in your business by implementing an automatic clamping feature along the production process.
Depalletising
Sometimes, it's not about adding something but rather, taking something away.
In the instance of depalletising, there is lots of opportunity to automate and streamline. The process of unloading items from pallets, usually to then load them into the next step of a manufacturing line can make use of robotic arms to move product, locating fences driven by actuators to align product and grippers to remove slip sheets or dividers, just to name a few.
We've seen a good number of our packaging customers make use of PHD Series GRM Standard Jaw Style Grippers, paired with PHD Series ESZ linear actuators to remove the cardboard or metal slip sheet that sits between each row of product on a pallet. The reliability, repeatability and robustness ensures the process is a set and forget scenario that improves productivity and profitability.
The take away; pun intended this time... but seriously, is there a step in your manufacturing process that could benefit from implementing an automation to take away a waste product or auxiliary component.
Tensioning of Rollers
Most belts stretch to some degree and as that happens over time, the effectivity of their task diminishes. In instances where a specific tension needs to be held, an actuator could serve as an excellent way to adjust and set belt tension. The addition of sensors and regulators could then also maintain the desired pressure based on a specific set point.
Another example where using a component such as the PHD Series PDK Crowder might benefit operations is with installation on machinery that then allows the manufacturer to adjust idler roller position, allowing control of throughput and pressure on the material passing through.
The take away; where in your manufacturing line, might you be able to consider how roller tension adjustment and/or regulation could improve productivity?
In conclusion
If it's a repeating process then any amount of automation has a multiplying effect. By this we mean, any investment in process improvement will continue to benefit, the longer it continues to serve in your business.
An initial investment might seem like a big outlay at the time but a great process improvement and automation will bring savings over and over again.