10 Mitos de La Automatizacion

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Top 10 misconceptions about automation

Myths, misunderstandings prevent fabricators from automating

By Randall Liette June 15, 2008

Fabricators frequently react to the idea of automation with powerful objections, manyof which are based on information that is obsolete, incomplete, or simply incorrect.

The reality is that automated systems can increase quality, profitability, and

production rates; reduce costs and setup times; improve safety; simplify machine

operation; and provide manufacturing flexibility.

Have you ever thought about automating the manufacturing processes in your plant? Whether youare an owner, production manager, manufacturing engineer, or machine operator, most likely youhave thought about automation. Unfortunately, many fabricators usually react to the idea ofautomation with powerful objections, many of which are based on information that is obsolete,incomplete, or simply incorrect.

Such objections deserve some deeper thought and analysis, especially considering the state ofcompetition in manufacturing these days.

Looking at the top 10 misconceptions that have stopped many automation opportunities dead intheir tracks reveals the reasoning behind them. It also provides some guidance in successfully

implementing automation in your facility.

1. It's Too Expensive

Often the initial reaction to automation—even for just a fewoperations—concerns affordability. You might think that youcan't afford to move forward and do this, but in many cases,the reality is that you can't afford not to do it.

Calculating your return on investment (ROI) is the first step.The initial price might seem hefty, but automating amanufacturing process will increase output while reducingcosts, mainly in direct labor and overhead. Including thesesavings in your calculations likely will improve the ROI.

Direct labor is often the biggest cost. It can account for up

to 75 percent of the total life cycle cost of a piece ofnonautomated capital equipment. Automation is a way tokeep labor costs down, with the added benefit of freeing

Click on images to view larger (Left) The new norm is a larger-than-ever variety of high-quality partsin smaller-than-ever lot sizes—requiring frequent changeovers—with

zero defects. Automation accommodates the new norm. (Right)

Frequent changeovers, not volume, may be the motivation to considerautomating your system. Consistency and quality, setup to setup, arebest addressed with well-executed autoation.

Click on image to view larger Setups are accomplished quickly

on automated tube bendingsystems by using dovetailed tooling

features and other quick-changetechniques.

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your most valuable asset—the employees—to apply themselves in more efficient and productiveways.

Some of the costs are objective and quantifiable. For example,replacing or retrofitting an older machine with automation canreduce energy costs. Automated equipment tends to runcontinuously and consistently, smoothing out the peaks inenergy demand. A representative from your local powercompany can work with you to determine the potential gains.

Remember to consider all the soft costs that might be reducedor eliminated by automating a process. You might find thatautomation:

Eliminates some of the preceding or subsequentprocessing steps.

Consolidates or eliminates tools, tool storage, andtooling changeovers.

Reduces work-in-process (WIP) because the machine runs continuously.

Reduces or eliminates rework and inspection because part consistency improves.

2. We Don't Have Enough Volume

A common misconception is that only high part volumes justify automation. Not so. The reality is that successful andflexible automation improves productivity, which results inhigher throughput. And to close the circle, improvedproductivity can open up new capacity that can be fil led withnew work, thereby increasing volume.

Higher productivity is also achieved through decreased cycletimes and reduced scrap or waste. These improvementsreduce WIP and increase inventory turns. Consistentproduction rates in turn permit efficient productionscheduling and facilitate scheduled preventive maintenance,keeping equipment operating in top condition and reducing

unexpected downtime.

Finally, automation also can result in a simplified operation(from an operator perspective) and a reduction in setup time.

3. We Change over Too Frequently

Frequent changeovers shouldn't be a reason not to applyautomation. In fact, this is a good reason to applyautomation. Frequent changeovers fuel the need for rapidsetups and simplified machine operations, two key benefitsthat may be realized with a well-designed and flexibleautomated system.

Three of the most efficient ways to set up tooling are:

Manual. Equipment operatorsmanually place quick-change gauge blocks inpredetermined positions using a color-codedsystem (or part numbering scheme) thatcorresponds to the job number.

Offline. Some system designs allow changeoversto be prepared offline while the equipment isrunning. After the current production run iscompleted, operators shut down the equipmentand quickly exchange the tooling.

Automated. A programmed setup makes the necessary changes, including gauge blockmovement, material handling changes, tooling swaps, and so on. Equipment operatorsare not involved.

Automated changeovers aren't limited to traditional tooling sets such as dies and molds.They also apply to conventional welding and laser processing cells that have several tool

Click to view image largerIntuitive graphics enable quickand accurate setup, operation,

and troubleshooting.

Click to view image largerIf you have not yet entered therealm of automation, start with

something simple, such as asingle-station, CNC tube bending

and handling system.

Click on image to view largerAutomated systems should have

flexible subsystems whereverpossible for future production

requirements. Handling materialwith servo transfers and robotsallows simple reprogrammingwhen manufacturing needs

change.





positions, allowing changeover at one station while another is running.

Once you have automated your processes, you might find that you can now afford toextend your part runs and reduce the changeover frequency. Extended production runs,balanced against a small amount of inventory, may not be a bad thing.

4. Our Work Will Change in the Future

Of course your work will change in the future. The life cycleof component or assembly programs in today'smanufacturing world is much shorter than it was just fiveyears ago. Programs that once ran eight to 10 yearstypically run three years or less these days. In concert withthis life-cycle reduction is an increase in the overall numberof programs.

Current manufacturing trends drive the need for flexibility. Awell-designed automated process enables product changeswithout requiring a complete retooling of your equipmentand rapid response to changes in demand or processes.

5. We Can't Afford to Put Our Best People on

the Machines"Our people are highly skilled fabricators. We can't turnthem into button-pushers." That's a common response.More often than not, using an automated system will allowyour best employees to apply their skills and talents inareas that are more beneficial to the company. Letautomation technology address the routine, repetitive, physically challenging tasks in your plant,and use the highly skilled workers in much more efficient and productive ways.

The simple task of moving parts from point A to point B is a perfect example for automation. Aphysically challenging task such as this can be done easily with a robot or pick-and-placeautomation. The assembly of components is another perfect fit for automation. Automate easytasks—those that don't involve reasoning, decision-making, troubleshooting, or problem-solving—and assign difficult tasks to the fabricators.

6. We Don't Know How to Run Automated Equipment

Automation technology can be a double-edged sword. Automation results in improved consistencyin terms of fit and form, so that final assembly is quicker and easier, and could be handled by low-skilled employees. On the other hand, automated machines are sophisticated and running themrequires more highly skilled employees.

The solution is training, training, and more training. With good technical training and documentationprovided by the system supplier or subsystem vendors, your employees will feel empowered towelcome new automation and feel that they are part of the team, ready and capable to make thesystem work to its full potential.

7. It's Too Difficult to Maintain Automated Equipment

On the contrary. Implementing a well-thought-out

automated system, one that has a modern control packagedesign, should simplify your maintenance efforts.

Whether you are buying an entirely new automatedproduction system or upgrading or retrofitting existingmachinery, a modern control package's features, such asfull-color screens, 3-D graphics, and PC-based controls,have enabled a giant leap in terms of online training andinstructions for setup, maintenance, troubleshooting, andrepairs. Intuitive, graphic-laden prompts and images allowoperators and maintenance personnel to be moreproductive than ever before. All of this is available at theoperator's console, eliminating the dreaded search for hard-copy documentation in some remote office. It also removesany excuse for bypassing the diagnostic steps and using

guesswork when troubleshooting.The control system also can monitor machine output, faults,

Click on image to view largerAutomated systems are designed

with operator safety in mind.Safeguarding schemes include

protective fencing with

tamperproof, interlocked doorlocking mechanisms; light curtains;

and parts loading and unloadingdevices such as dual rotary

turntables.

Click to view image largerMany automated systems are

available in standardizedpackages. After you identify a

family of parts to be processed,your system integrator will workwith you to size a system and

recommend the features andfunctions for optimized output and





and downtime, creating a history of events that can help topredict future component failures or highlight operator setuperrors that could be eliminated with additional training orprocess enhancement. Tracking machine downtime alsocan help to schedule preventive maintenance.

8. We Are Very Concerned about Safety

Automated equipment can enhance safety in the shop. A reliable equipment integrator followscurrent safety guidelines and provides documentation and training to help keep employees safe.For equipment upgrades, control system integrity and reliability can be improved with automation.Security levels, including password protection or keyed access, can be built into the system.

When coupled with good training techniques, effective integration of machine safeguarding andcontrols reduces the risk to the operators, enhances their awareness of danger zones, and providesa safe and productive operating environment.

9. We Don't Have Time for This

Based on the level of competition U.S. manufacturers face from low-cost competitors in developingnations, can your company afford to put this off any longer?

Relentless competition is forcing companies to apply new operational initiatives and revise cost

models on a broad scale. You can't control the state of competition or your competitors'manufacturing practices, so your only recourse is to focus your attention on the areas that you cancontrol—your practices and your processes, both of which can be enhanced with automation.

10. Where Do We Begin?

We have all heard the old adage about having to start somewhere.

Another maxim states, "You can't move forward by standing still." So, when considering the movetoward an automated production floor, think incrementally—tackle small, manageable projects atfirst. There are several good reasons for this, but the bottom line is that you want your first ventureinto automation to be successful, and a small project is easier to manage, control, and documentthan a large project. Also, communicating the results of implementing a small project is likely to beeasier than doing so for a huge project.

Start by gathering production data on your current processes. Select one manageable process and

automate it, then measure and document the new process's uptime, downtime, scrap rates,changeover times, and quality. Concerning downtime, document the time of day that the system isdown, the reasons (including all upstream and downstream processes), and the solutions. Keep adetailed log, including both text and photographs.

When you have sufficient data, analyze it. Look for trends, both good and bad. You might discoverthat upstream or downstream processes limit the throughput of the automated system. Develop aplan to use what you learn, whether it means more training, making changes to the equipment, orreconfiguring other processes in your plant.

Use the first project as a foundation for automating other processes in your plant.

This article can be found at:

http://www.thefabricator.com/AutomationRobotics/AutomationRobotics_Article.cfm?ID=1982

flexibility.

Contact us at: FMA Communications, Inc. 833 Featherstone Rd. Rockford, IL 61107 815-399-8700 E-mail: info@th

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10 Mitos de La Automatizacion