Robotics in Manufacturing
PROJECT SCOPE
System Design & Integration, Electrical & Mechanical Engineering, Robotic Equipment and Programming, Controls, Mechanical-Electrical Installation, Custom Fabrication
INDUSTRY
Manufacturing
Summary
Solutions for robotics in manufacturing span an ever-expanding range of tasks. New advancements such as co-bots simplify customization. And as always, robots continue to help us transition dangerous or repetitive work away from our team members.
However, robots do not achieve these outcomes as a stand-alone solution. Productive, cost-effective implementation requires the integration of robots with the other elements of our operation.
In this article, we offer a big picture view of the terminology and uses of robotics in manufacturing, as well as a case study that demonstrates the integration of robotics into a real-life manufacturing system.
Understanding Robotics in Manufacturing
“Are robotics relevant to my operation?”
Chances are good that you are thinking about robotics.
It is also likely that you find the complexity of the topic to be daunting.
To make matters worse, unfounded estimation of the costs to embrace robotics and automation keeps many from even investigating the subject.
The real question is: What is the actual value of these technologies, and how can they impact our business?
SilMan wants to help.
We’ve created a broad overview of the terminology and capabilities of robotics in manufacturing.
In the process, we will also look at a real-life system recently designed and installed by the SilMan Material Handling team.
Speak to a key team member on this project
Meet Tommy Ethridge
For more information about this project or related topics, contact Tommy by email or call directly at 662.260.2544.
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Elements of Robotics in Manufacturing
The primary challenge for robotics in manufacturing is the need to re-envision our processes. Despite all the science and technology at play, it still comes down to imagination!
There are many areas where robots have become established in manufacturing or assembly processes. For instance, we have all seen the dramatic images of robots in the weld-up phase at an automotive plant. But that is far from the full extent of their use.
Industries commonly employing robotics include electronics, appliances, building products, food & beverage, and healthcare facilities.
Task commonly fulfilled by robots include palletization, packaging, labeling, painting, and assembly.
You may also see them employed for human or mechanical actions, such as inspection, pick and place, loading and unloading, and induction.
The Power is in the Package
If you have seen a FANUC robot at work, it is not hard to be dazzled by these machines. Powerful, precise, and beautifully designed.
However, despite this brilliance, robots are powerless by themselves.
The success of your journey into robotics is 100% reliant on the integration of elements upstream and downstream from the unit.
Complementary solutions include conveyance, controls, imaging, HMI, printer/labeler, and workspace design.
It’s Not About the Robot
Product knowledge and customer awareness win the day
Long before the design and installation of the system, SilMan demonstrated a deep knowledge of the client’s system during the proposal phase. In fact, understanding the client’s operating style and secondary challenges beyond the proposed system were decisive factors in winning the contract.
Furthermore, these same insights were vital to our interactions with the customer’s engineering team to make final equipment determinations. SilMan’s suggestions resonated with the company’s approach to existing equipment and process considerations within the plant.
For instance, the introduction of FANUC 3D Vision was a game-changer. The FANUC 3DV 600 camera provides seamless integration with the FANUC M-20iD/25, and along with it, the power of its machine learning tool.
But just as important, the 3DV600 also provides seamless integration with the FANUC controllers, which added much-needed space by reducing the amount of peripheral equipment around the line.
Product Review
Want to learn more about FANUC products? SilMan team member Tommy Ethridge has reviewed the FANUC Robots and 3D Vision equipment featured in this case study.
Infeed/Outfeed, Pick and Place, Inspection
Case Study: Robotics in Manufacturing System
SilMan provided a conveyance and control system for a leading manufacturer. The solution handled parts and products in and out of manufacturing elements, provided automated inspection (accept/reject), and transferred the parts between manufacturing stages.
Due to the nature of the items handled, the system is a hybrid of robotic automation and human operators.
Let’s take a look at the tasks accomplished and the equipment deployed in this system.
- Task: Parts Handling
- Robots: FANUC M-20iD/25 robot with FANUC 3D Vision
- Equipment: Conveyors, robots, EOAT, safety fencing, cameras, barcode readers, sensors, programming, and integration.
- Controls Robotic picking system with multiple levels of process controls.
- System: Induction, multiple infeed/outfeeds, transfer, convey to a manual inspection station, and palletization.
- Data: Imprint ID, scan and assign to the database, scanners inspect the part, inspection queries database for the status of part
- Servo End-of-Arm-Tool (EOAT)
- Refresh rate 3.5 seconds, conveyor moving at 17 parts per minute
- No operator intervention for part changes. Automatically adjusts based on “Recipe” for each item, as programmed.
- Identify part with 3D vision, automatic adjustment to correct part configuration.
- Automatic reset for each change of product.
What is a “Recipe”?
The “Recipe” is a unique set of parameters required for each part that passes through the system.
For instance, directives for the EOAT may include flexing for changing diameter, height, style (round, oval, racetrack), as well as orientation and positioning for 2D printing. This programming also applies to printers themselves for barcode format and location.
The Recipes take full advantage of the flexibility of the end-of-arm tools. No operator intervention or reset of equipment is required since the EOAT automatically adapts for size and shape when changing products or parts.
Robotic System Integration at SilMan
The primary value that SilMan repeatedly provides to clients is the close coordination of our internal teams: account management, engineering, controls, mechanical, and electrical field teams.
This “one-stop” service by SilMan delivers time-savings and efficiency to every stage of project development and execution. It also provides continuity during long timelines and complex system designs.
All of these qualities came into play during this project.
Scope of Work
Notably, the variety of parts handled and equipment needed by this system demanded a high level of controls design and programming.
- Engineering: Mechanical & Electrical Engineering,
- Project & Site Management
- Procurement
- Fabrication: Custom Fabricated Operator Platforms (2)
- Installation: Mechanical and Electrical
- Controls Design and Programming
- Graphics Development: Screen Architecture
- Factory Acceptance Test (FAT trials)
- Training & Security Procedures
- Onsite Commissioning
The Value of Robotics in Manufacturing
Measuring Success
Beyond the factory floor, the adoption of robotics in manufacturing strategies offers a wealth of new horizons, including sales and marketing.
More importantly, they can positively impact recruitment and team culture. Manufacturers who deploy high-tech equipment can attract and retain qualified team members who want to work with the latest technologies.
And perhaps most importantly, the mere presence of these solutions in your facility brings a forward-looking atmosphere to management and labor alike.
“What to do next?”
This is by far the most common question we hear from our customers and friends.
Rest assured, giant steps are not necessary. A measured, strategic plan can boast productivity now and set the stage for cost-effective expansions in the future.
Our teammate David Rebata, who leads the SilMan Material Handling team, has created an article about this very topic: “4 Tips to Future-Proof Your System.” In it, you will find lots of ideas and examples to help you make your next step.
And, of course, you may reach me anytime to learn more about implementing these solutions in your facility.
About the Company
SilMan Industries (previously SilMan Construction) is based in San Leandro, Calif., with Engineering and Field Operations offices in Tupelo, Miss. The firm provides integrated turnkey solutions in the Industrial, Manufacturing, Distribution, and Public Works sectors.
Notably, in 2010 SilMan Industries was contracted to dismantle and remove the NUMMI assembly line in Fremont, Calif., transport the equipment, and reinstall the system in Blue Spring, Miss., establishing Toyota Motor Manufacturing Mississippi (TMMMS). This high-visibility project ignited the company’s meteoric growth, laying the foundation for SilMan’s national service area.
For more information, please visit www.silmanindustries.com/about.
SilMan’s renowned in-house team of system integrators, engineers, and controls professionals provide industry-leading material handling solutions for robotics in manufacturing. Noted for their communications and transparency throughout the development and execution of projects. The multiple-skilled team has a national footprint, providing materials handling systems and solutions throughout the United States. SilMan is national, serving all cities. This includes: Oakland. Los Angeles. Phoenix. Dallas. Chicago. Atlanta. Bowling Green. Charlotte. Huntsville. Indianapolis. Seattle. Kansas City.
