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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, many
of which are based on information that is obsolete, incomplete, or simply incorrect.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.

Click on images to view larger

(Left) The new norm is a larger-than-ever variety of high-quality parts
in 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 consider
automating your system. Consistency and quality, setup to setup, are
best addressed with well-executed autoation.

Have you ever thought about automating the manufacturing processes in your plant? Whether you
are an owner, production manager, manufacturing engineer, or machine operator, most likely you
have thought about automation. Unfortunately, many fabricators usually react to the idea of
automation with powerful objections, many of which are based on information that is obsolete,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 of
competition in manufacturing these days.
Looking at the top 10 misconceptions that have stopped many automation opportunities dead in
their 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 few
operations—concerns affordability. You might think that you
can'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 a
manufacturing process will increase output while reducing
costs, mainly in direct labor and overhead. Including these Click on image to view larger
savings in your calculations likely will improve the ROI. Setups are accomplished quickly
on automated tube bending
Direct labor is often the biggest cost. It can account for up systems by using dovetailed tooling
to 75 percent of the total life cycle cost of a piece of features and other quick-change
nonautomated capital equipment. Automation is a way to techniques.
keep labor costs down, with the added benefit of freeing

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your most valuable asset—the employees—to apply themselves in more efficient and productive
ways.
Some of the costs are objective and quantifiable. For example,
replacing or retrofitting an older machine with automation can
reduce energy costs. Automated equipment tends to run
continuously and consistently, smoothing out the peaks in
energy demand. A representative from your local power
company can work with you to determine the potential gains.
Remember to consider all the soft costs that might be reduced
or eliminated by automating a process. You might find that
automation:
Click to view image larger
z Eliminates some of the preceding or subsequent Intuitive graphics enable quick
processing steps. and accurate setup, operation,
and troubleshooting.
z Consolidates or eliminates tools, tool storage, and
tooling changeovers.
z Reduces work-in-process (WIP) because the machine runs continuously.
z Reduces or eliminates rework and inspection because part consistency improves.

2. We Don't Have Enough Volume

Click to view image larger
If you have not yet entered the
realm of automation, start with
something simple, such as a
single-station, CNC tube bending
and handling system.
A common misconception is that only high part volumes
justify automation. Not so. The reality is that successful and
flexible automation improves productivity, which results in
higher throughput. And to close the circle, improved
productivity can open up new capacity that can be filled with
new work, thereby increasing volume.
Higher productivity is also achieved through decreased cycle
times and reduced scrap or waste. These improvements
reduce WIP and increase inventory turns. Consistent
production rates in turn permit efficient production
scheduling 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 apply
automation. In fact, this is a good reason to apply
automation. Frequent changeovers fuel the need for rapid
setups and simplified machine operations, two key benefits
that may be realized with a well-designed and flexible
automated system.
Three of the most efficient ways to set up tooling are:

z Manual. Equipment operators

manually place quick-change gauge blocks in Click on image to view larger
Automated systems should have
predetermined positions using a color-coded
flexible subsystems wherever
system (or part numbering scheme) that possible for future production
corresponds to the job number. requirements. Handling material
z Offline. Some system designs allow changeovers with servo transfers and robots
to be prepared offline while the equipment is allows simple reprogramming
running. After the current production run is when manufacturing needs
completed, operators shut down the equipment change.
and quickly exchange the tooling.
z Automated. A programmed setup makes the necessary changes, including gauge block
movement, material handling changes, tooling swaps, and so on. Equipment operators
are 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

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

Once you have automated your processes, you might find that you can now afford to
extend 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 cycle
of component or assembly programs in today's
manufacturing world is much shorter than it was just five
years ago. Programs that once ran eight to 10 years
typically run three years or less these days. In concert with
this life-cycle reduction is an increase in the overall number
of programs.
Current manufacturing trends drive the need for flexibility. A
well-designed automated process enables product changes
without requiring a complete retooling of your equipment Click on image to view larger
and rapid response to changes in demand or processes. Automated systems are designed
with operator safety in mind.
5. We Can't Afford to Put Our Best People on Safeguarding schemes include
protective fencing with
the Machines tamperproof, interlocked door
"Our people are highly skilled fabricators. We can't turn locking mechanisms; light curtains;
and parts loading and unloading
them into button-pushers." That's a common response.
devices such as dual rotary
More often than not, using an automated system will allow turntables.
your best employees to apply their skills and talents in
areas that are more beneficial to the company. Let
automation 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. A
physically challenging task such as this can be done easily with a robot or pick-and-place
automation. The assembly of components is another perfect fit for automation. Automate easy
tasks—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 consistency
in 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 them
requires more highly skilled employees.
The solution is training, training, and more training. With good technical training and documentation
provided by the system supplier or subsystem vendors, your employees will feel empowered to
welcome new automation and feel that they are part of the team, ready and capable to make the
system 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 package
design, should simplify your maintenance efforts.
Whether you are buying an entirely new automated
production system or upgrading or retrofitting existing
machinery, a modern control package's features, such as
full-color screens, 3-D graphics, and PC-based controls,
have enabled a giant leap in terms of online training and
instructions for setup, maintenance, troubleshooting, and
repairs. Intuitive, graphic-laden prompts and images allow Click to view image larger
operators and maintenance personnel to be more Many automated systems are
productive than ever before. All of this is available at the available in standardized
operator's console, eliminating the dreaded search for hard- packages. After you identify a
copy documentation in some remote office. It also removes family of parts to be processed,
any excuse for bypassing the diagnostic steps and using your system integrator will work
guesswork when troubleshooting. with you to size a system and
recommend the features and
The control system also can monitor machine output, faults, functions for optimized output and

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and downtime, creating a history of events that can help to

predict future component failures or highlight operator setup flexibility.
errors that could be eliminated with additional training or
process enhancement. Tracking machine downtime also
can help to schedule preventive maintenance.

8. We Are Very Concerned about Safety

Automated equipment can enhance safety in the shop. A reliable equipment integrator follows
current 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 and
controls reduces the risk to the operators, enhances their awareness of danger zones, and provides
a 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 developing
nations, 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 can
control—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 move
toward an automated production floor, think incrementally—tackle small, manageable projects at
first. There are several good reasons for this, but the bottom line is that you want your first venture
into automation to be successful, and a small project is easier to manage, control, and document
than a large project. Also, communicating the results of implementing a small project is likely to be
easier 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 is
down, the reasons (including all upstream and downstream processes), and the solutions. Keep a
detailed log, including both text and photographs.
When you have sufficient data, analyze it. Look for trends, both good and bad. You might discover
that upstream or downstream processes limit the throughput of the automated system. Develop a
plan to use what you learn, whether it means more training, making changes to the equipment, or
reconfiguring 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

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