Robot-aided production in SMEs
Automation is a term that brings large-scale manufacturing and giant machinery pools to mind. But automated processes aren’t just for major production plants: Increasingly, small, specialized companies are relying on robots as well. But first, they have to ask themselves whether robot deployment is in fact economical in their specific environment. The answer depends on overall equipment effectiveness (OEE). Moving to software-based offline programming (OLP) can play a key role in improving it.
Robot programming – manual vs. offline
In manual programming, a programmer “feeds” the robot the necessary movements, one by one. This so-called teach-in method thus requires close interaction with the machine and is often time-intensive, especially when it comes to making changes.
In contrast, OLP permits computer-based program generation and optimization without interrupting ongoing production. Programs are created, validated and adapted in a virtual 3D simulation environment, so that any errors can be revealed and corrected before the program goes live. This significantly boosts the quality of the completed program.
When does the switch to OLP pay off?
A simulation tool is not a must-have for any and all manufacturing contexts. In traditional large-volume production, where production lines are installed once and then make the same components for lengthy time periods, manual programming is often the right choice. But in the following scenarios, a changeover to offline programming can often be a meaningful solution:
- Small lot sizes and high product variance: If a company produces many different components in small lots, it often needs to adapt its robot programs. Manual programming means lengthy production line downtimes, and these have an adverse effect on overall equipment effectiveness (OEE). The use of OLP means that production can continue unimpeded.
- Frequent component changes: OLP is particularly beneficial if a business constantly needs to modify its products or components. Changes can easily be made and tested in the simulation environment, again avoiding costly production downtimes.
- Complex parts geometries and sophisticated processes: In cases where production involves complex components or procedures, OLP enables simulation and optimization of advanced robot programs before they are handed over to production. This prevents costly mistakes.
- Multiple robot brands: Machine pools often include various brands of robots, each of which requires its own software. In such situations, OLP offers a standardized platform for all robot programming and management.
- Collision prevention and added security: Complex processes may pose the risk of collisions between the robot arm and the component. OLP provides a secure environment for early-stage simulation and thus prevents costly damage to machinery and products.
- Solving labor shortages and protecting knowhow: OLP helps create automated processes and user-friendly software that open up new task fields to less experienced labor. It also conserves valuable knowledge that could be lost when highly trained staff leave the company.
Balancing costs and benefits
In many instances, the benefits described above will lead to a reduction in unit costs as well as overall manufacturing costs. Although the change to offline programming requires initial investments, these are offset by cost savings and increased efficiency. Conducting a thorough cost-benefit analysis is therefore well worth your while – you may be surprised by the results!
Key figures from successful client projects
What costs do you have to expect?
On the cost side, OLP programs generally require a software license, with costs varying by provider and functional scope. Add to that the operating costs: To maintain its efficiency, the software solution needs to be serviced and updated regularly. In all cases where this has not already been done, we recommend calibrating the production facility prior to the installation of the simulation tools. Training workshops are needed to ensure that staff have the skills they need to operate the new software. Additionally, the new level of automation may require process modifications and, in some instances, adaptation of upstream or downstream processes as well.
What benefits does a switch to offline programming offer you?
Conversion to automation with the aid of OLP offers businesses a wide range of benefits:
- Reduced programming times: The software recognizes geometries and optimizes robot movements automatically. This yields an enormous reduction in programming times. Practical example: The auto supplier Johs. Pedersen A/S was able to cut the time spent on robot programming by 90 percent.
- Reduced cycle times: The use of OLP accelerates processes and reduces plant downtime. Practical example: Aerospace supplier Diehl Aviation shortened its cycle times by 40 percent and increased the degree of automation in the production of complex components.
- Reduced quality costs: OLP reduces errors and reworking effort. Simulation-based testing reduces quality costs because it recognizes and remedies errors before they impact production. Practical example: Crane and excavator maker XCMG succeeded in reducing its quality costs by 30 percent.
- Reduced operating costs: Using 3D simulation to define optimal component orientation saves time and costs otherwise needed for expensive rigs and fixtures. Practical example: Forklift maker CROWN achieved a significant reduction in tool engineering effort.
- Improved productivity and employee satisfaction: (Partial) automation of programming enhances productivity because even staff without special robot skills can participate effectively. This reduces the need for skilled labor. Practical example: Thanks to OLP, forklift maker CROWN achieved greater employee satisfaction and loyalty.
A handout for starting your decision-making process
A boost for your manufacturing efficiency?
As many real-world examples show, the changeover from manual programming to OLP offers a wide range of significant business benefits, especially in complex, flexible and dynamic manufacturing environments. The users profit from faster, more efficient and higher-quality robot programming. Although the introduction of a simulation tool involves certain costs, these investments are in many instances quickly redeemed by the gains in productivity and the reduction in production costs.
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