Evaluate Assembly Line Automation To Properly Fit Your Manufacturing
Because of the complexity and the number of tasks that are done in the product assembly
operation it is a good idea for management of manufacturing to evaluate whether assembly line automation will fit well into current operations. Understanding the circumstances where assembly line automation can make manufacturing more efficient and reduce costs is definitely the first task that must be done before starting an automation project.Assembly line automation can best be implemented for products that are very stable in design and mature in the marketplace. It is usually not a good idea to try to set up assembly line automation for products that may not have their design changed in some way in the near term. Such changes can cause the required re-configuration and possible installation of different assembly line devices. This will certainly consume more time and expense and delay the production of products. The trickle down effect of this delay could damage the launch of a new product, if marketing has made the marketplace aware of the imminent release of a new product. Forethought and planning by management are good things in this case.
There are criteria that can be used to guide management in the evaluation of assembly line automation. Some of these are very practical, but reviewing all the aspects of potential automation can be a great benefit to successful automation of an assembly process. The characteristics of the product that is to have its assembly automated should be reviewed. Usually a product that has a small number of parts or sub-assemblies that make up the final assembly is a good candidate for automation. Having a small number of parts should make the assembly of the product much more manageable by automation. The product should have parts that would be easily inspected by automation. If the parts cannot be inspected effectively by automation, then it might not be a good idea to consider assembly line automation. One defective part could shutdown the entire production line, if the process is automated, and even damage the equipment or raw materials, depending on how the assembly is performed.
Products that have less complexity in assembly are the best ones for assembling by automation. Complicated joining procedures and the use of complex fasteners sometimes make it difficult to optimize the automated assembly process. The parts of the product should be light enough to be easily manipulated by automation devices to keep the production rate at what is expected. Having a stable design usually dictates that the product has had the complexity of its assembly removed in earlier design iterations. At the point of setting up assembly automation the product should be through its final design phase and at its optimum best for assembly.
A careful look should be taken at the length of time that is required to assemble the product manually. Automation can reduce assembly time for most products. If there is quite a bite of re-work that has to done for the product either during or after manual assembly, then automation can help to remove these from the list of expenses for the manufacturing operation. The production rate of manual assembly is usually much lower than the automated assembly rate. Management needs to determine if the product in question is demanded in higher volumes than is currently being met by manual production rates. If the demand for the product is not high enough to warrant the expense and effort to implement automated assembly, then there is little need to do so.
Management will need to determine if the appropriate personnel are available for operating the assembly equipment. If this is a new concept in the company, employees will need to be trained or hired to fill the operator and maintenance positions. Sometimes employees will volunteer, if given the chance, to upgrade their skill sets by attending training to become operators of automation. Reviewing the skills of current employees that are likely to do well in such positions could produce excellent staff for this purpose. Employees who have been on the manufacturing staff for a while will know the company policies and procedures and be able to help get automation up and running quickly. Bringing new employees on staff to perform such functions may take longer than using current employees.
Considerations must be taken of any labor agreements that are in place with labor unions before asking for employees to move to new positions withing the company. Sometimes there can be complications for the entire manufacturing operation if this is not addressed prior actually planning automation for assembly.
Company management should also consider their own capabilities when considering the implementation of assembly automation . Management should have the background and ability to make decisions about automation that will be best for company operations. If this is not the case then it is best for management to rely on the expertise of consultants in the field to give them guidance to make the proper decisions for the good of the company.
by: John Mitchell