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Industrial Automation Trends 2024

As 2023 draws to a close, the industrial automation landscape continues to evolve. Artificial Intelligence (AI), Machine Learning (ML), Collaborative Robots (cobots), Internet of Things (IoT), 3-D printing and other technology advances continue to push industrial automation in new directions. Recently, a group of experts shared their insights about industrial automation trends and what 2024 may hold.

The experts:
Jim Beretta, Brand and Marketing Consultant, Customer Attraction Industrial Marketing, moderator for the webinar hosted by the Association for Advancing Automation (A3)
Joe Gemma, Chief Revenue Officer, Wauseon Machine
Jeff Wells, Director, Automation Sales, Ehrhardt Automation Systems
Tom Rozema, Chief Revenue Officer, JR Automation
Joe Wykes, Chief Revenue Officer, Vention

One of the legacies of the global pandemic is a continued global labour shortage. Wells noted that many customers are exploring automation for the first time, either as a way to automate functions to allow them to redeploy existing personnel, or as a way to meet continued labour shortages. This creates unique challenges for robot integrators, as new customers may be unfamiliar with the skillset required to support the automation, and may not have the necessary budget allocation. “The earlier the robot integrator can be involved in the project discussions, the easier it is to ensure that all the customer’s needs are met.”

Wykes noted that as technology becomes more accessible, the “inevitability of automation” has shifted automated solutions from a “nice to have” to “need to have.” In addition, companies need to be able to quickly produce new products in response to customer demand, and automation provides the speed to move from idea to execution. 3-D printing is becoming more mainstream, and with the process cycle improving, many companies are adopting 3-D printing solutions.

Many materials handling and warehousing operations are not only increasing the use of automated transfer vehicles (ATV) and autonomous mobile robots (AMR), they are adding cobots to ATV or AMR to complete additional tasks.

Wykes added digital twin and simulation allows companies to “de-risk” a project with a “like for like experience” to design, experiment and test a solution prior to execution and implementation. Gemma added that vision technology is providing an affordable innovative solution, especially when combined with ML and AI, 4D vision or lighting. Rozema noted they have seen broader use of digital twin applications to gain efficiencies in many industries with multi-sku environments or multiple product lines.

As part of this trend, there has been an increase in projects for low volume, high mix environments that require flexibility and fast or automated changeovers. In addition,many companies are scaling back internal engineering in favour of outsourcing technology or process improvements leveraging expertise readily available. Alternatively, companies are also making a skillset investment in technology-enabled engineers to drive automation in the businesses, or find ways to use automation to deliver more faster.

While many automation companies eat,sleep and breath big data, IoT and Industry 4.0, for customers it is often a case of diametrical opposition. Some customers have fully embraced big data, smart applications and IoT, while others are unfamiliar or have not added smart systems for managing the data, or allowing IoT connectivity. That can be a challenge for automation companies trying to introduce smart automation solutions or update existing infrastructure to include IoT and Industry 4.0 applications. Software, data and applications can provide opportunities for nimble, agile responses for manufacturers, and data management will become more important. AI and ML can provide assistance with adding smart solutions to a manufacturing operation that may have piecemeal automation solution.

Part of the challenge of big data is storage. In the advent of 5G, Cloud-based digital architecture has seen a shift. Improvements in security technology and protocols provide better digital solutions and allow for enhanced global technology connectivity, while adding a layer of protection against cyber attacks.

The labour shortage is not unique to manufacturing; robot OEMs and integrators also have trouble finding and retaining skilled talent. Apprenticeship programs were discontinued, and interest in manufacturing declined. In the advent of the new technology, the industry is partnering with education institutions to shape curriculum to spark interest in cutting edge manufacturing. Involvement in the school system with events like First Robotics generates excitement and interest from an early age. Once employees have been hired and trained, by providing enhancement opportunities, investing in management and providing flexible or hybrid work options companies have a better chance of retaining skilled and valuable personnel.

A legacy of the global pandemic was the resulting supply chain issues due to shutdowns and shipping delays. While there is a great deal of “chatter” about reshoring, in reality it has been more a “nearshoring” situation where companies have moved plants to North America but located them in Mexico rather than the United States. Rather than “reshoring”, companies are “stayshoring”, investing in factories in North America to ensure equipment and technology will be readily available in the future.

Looking forward into 2024, one of the technologies that Rozema thinks will continue to advance is generative AI to leverage technology and historical data to push out responses faster. Wells noted that he expects more consolidation in the automation industry in 2024, while Wykes felt that cobots will continue to provide opportunities for more widespread adoption especially when paired with simulation applications to make adoption easier and faster. He also noted that the trend towards “not if, but when” and “I may not have been first but I shouldn’t be last” will continue to drive innovation and adoption of the technology. Gemma is hoping for a national policy to support automation and development of the technology. The prevailing opinion that technology somehow takes jobs away is changing, and many countries in the world already have a national strategy.

Finally, a number of technology companies caught the attention of the panel in 2023.

Here are the ones to watch (in no particular order):
Apera AI 4D vision
Olis Robotics
Formic
Agility Robotics
Dexterity
Keyence
Flexibowl
Tulip
Universal Robots
Flexbotics

If you have an automation project and would like to learn more about some of the industrial automation trends from one of our automation experts contact us at sales@ehrhardtsolutions.com

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Reducing Automation Downtime

Unscheduled downtime wreaks havoc on production schedules and stresses people to make up for lost time while protecting cost objectives.  Strategies for minimizing downtime used to focus on scheduled equipment maintenance and the ability to quickly repair anything that went wrong. Now, with automation, there is software and technology as well as hardware to manage. 

Having good service agreements and skilled repair people are still essential for keeping production running smoothly. However, technology has changed the playing field for preventing downtime by making data more accessible. Knowing exactly what is going on in your production process can completely alter the way problems are managed and mitigated. Data eliminates much of the guesswork about how much maintenance is needed, and what causes downtime. 

A system with built-in intelligence can also start to recognize patterns such as a temperature shift that regularly precedes equipment failure. Knowing the precursors to equipment failure can help preventive maintenance be much more effective. Critical equipment can be set up with monitoring sensors so that you aren’t limited to doing maintenance on a schedule, but rather by what the equipment actually needs.

To minimize downtime, multiple strategies can and should be deployed. We’ll explore some of the most effective strategies in this article. 

Identify root causes

What if downtime isn’t caused by machinery malfunction, but rather by process inefficiency? By monitoring the production line and gathering data, inefficient processes can be identified. For example, does a robotic arm “fail” because there is no part ready for it to pick up? The root cause of that problem lies further downstream, even though it might be the stopped robot that causes a production downtime event.

Streamline setups

Is setup taking much longer than it should? When retooling takes longer than it should, it moves from planned downtime to unplanned. In some cases, downtime costs may outweigh the cost of having extra equipment available to eliminate time lost to setup. It’s a good idea to re-examine setup processes to look for ways to improve efficiency.

Prevent human errors

Humans make errors, but some of them can be prevented. Knowing which errors are made repeatedly can help identify training needs or a procedure that needs optimization to minimize errors. In some cases, a “poka-yoke” may be needed. Poka-yoke is a Japanese term for mistake proofing. An example would be re-designing a component or tray so that it can only be oriented the correct way.  Eliminating the possibility to do things wrong makes training new operators easier, and minimizes mistakes that cause downtime. 

Mitigate supply chain issues

Keeping a minimal inventory works well when you can count on parts arriving just in time. Unfortunately, supply chain issues have compromised inventory predictability. Downtime caused by “waiting for parts” needs to be identified and addressed with procurement personnel. Reliability should be factored in to decisions about sourcing essential parts, and setting minimum inventory levels.

Allow time for equipment care

When setting KPIs, be careful to ensure that machine operators aren’t penalized for taking the time to stop and care for equipment. The old adage “a stitch in time saves nine” applies here. If operators are under pressure to keep production running at maximum speed at all times and not stop except for dire circumstances, they won’t be able to make small adjustments that can prevent a bigger stoppage later. 

Instead, build in time allowances and rewards for operators who do take the time to check, care, and maintain equipment to keep it running optimally even after their shifts are over.

Train operators using digital tools

Having properly trained operators is essential to keep equipment running; however, training people can slow down production. To optimize training, take advantage of simulators and digital options to allow adequate time for explanations and a complete understanding of how all equipment works, without the pressure of training on a running production line.

Multi-faceted strategies, data analysis, and digital tools offer many opportunities to minimize automation downtime.

To learn more about reducing downtime in your next automation project, contact sales@ehrhardtsolutions.com

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Reducing Risk in Automation Systems

Chad Ramsey, Director of Automation for Ehrhardt Automation Systems recently participated in The Robot Industry Podcast to share insights about how to reduce risk in automation.

Minimize Automation project risks
Some of the biggest risks in automation include cost, project delays, time to integration, design time and technology challenges. There are a number of things that can be done to minimize these risks during an automation project.

  1. Comprehensive Specification Document
    One of the most important aspects of an automation project is the specification document. You need to have a good sense of what the project goals are, what components will be needed, and what you want the results of automation to achieve. Involving an integrator early in the process can ensure that your Request for Quote (RFQ) or Request for Proposal (RFP) is comprehensive and will achieve your desired results.
  1. Qualify vendors early
    If you know what type of functions you want to automate, you can qualify 3rd party suppliers early in the process. Automate the functions that make sense in your operation, and are good candidates for automation. One of the biggest risks manufacturers are facing is a labour shortage, and robots can cover some of the shortfalls and labour challenges.

It’s important to remember there is nothing wrong with a manual integration station for components that may not lend themselves easily to automation. Collaborative robots are designed to work in tandem with their human counterparts, and processes can be custom-designed to switch seamlessly from robot to human and back.

  1. Design for Assembly or Manufacturability
    Ehrhardt Automation specializes in 100% custom design integrations, and can work in tandem with manufacturing engineers to ensure the final project meets the needs of each client. It is important the integrator look at both the project as a whole and then at each component, including technical expertise at the client’s company, technological readiness-how open and familiar existing staff is with automation, risk analysis, safety concerns and then create an integration project solution to decrease overall manufacturing risk.
  2. Staff
    Staff may be hesitant to support automation, seeing it as a way of replacing staff with machines. Ramsey said, “The earlier you can get your staff involved the better, really get their perspective and get their understanding. They may have some skills, feedback or perspective that you are not aware of. Getting overall perspective and understanding of the problems from the point of issue or operation is key.”

While initial training is essential and will provide a level of comfort, it is also important to include training in the budget in subsequent years. There is often a concentration on initial training, but retraining may not occur, and it is important to provide refreshers for ongoing success and to keep certifications active. In addition, ensuring more than one person is fully trained on the operation can both provide opportunities for peer training, and avoid situations where the only person who understands every aspect of the machine leaves the company, leaving no one ready to step in.

Finally, identify facility champions who can become subject matter experts, and become the point people for training and questions. Peer acceptance is the easiest way to widespread acceptance, especially if staff see the new potential and opportunities the automation is providing.

Importance of Specification Document
It bears repeating that a comprehensive specification document is the key to a successful automation project. Partnering with an integrator early in the process can ensure that a company new to automation will have all the important sections covered in the specification document.

The basis of any specification document is a clear understanding of what the automation project hopes to achieve. It can then include different sections, depending on the type and scope of automation.

The vendor document is often a standalone document within the specification document. It will often be a general document and then the specification document is equipment specific, and includes information such as run time, cycle time, piece to piece, including an operator. The more definition is the basis for a strong specification document.

Supplemental documents could include engineering drawings, or a call with an integrator to clarify and define all the specifications and requirements.

Engineering Study
Depending on the type of project, either the integrator, the customer, or both can request an engineering study as part of the proposal. This is often completed on projects that have higher elements of risk.

Engineering studies are intended to ensure that all components will work as intended, following safety protocols and tolerance levels. They ensure that all parties will be satisfied with the final project, and can include a physical design, a build and/or an integrated test with or without the customer present. Ramsey advised an engineering study can involve “10-30% of the project cost and that can be carried into the next stage of the project. Generally components and equipment that is acquisitioned as part of the engineering study can be moved into the main project, assuming the engineering study goes well.”

Common automation projects that would include an engineering study include:

Vision Robot automation vision systems can be impacted by light, the environment, shine or reflection, or even the colour of the part, so it is common to request an engineering study. It’s a relatively cheap and easy study, and 3rd party providers will often partner with the integrator to provide the vision engineering study as a value-add.

Robotics Some of the common engineering studies for a robotics project could include whether the robot can deal with non-standard, malleable or non-rigid parts or if a manual integration station will need to be incorporated.

New Technology Integrations that include new technology, such as 3-D printing or vision or IoT compatibility will request an engineering study to ensure the technology performs the way it needs to.

Deliverables from an engineering study can be as simple as tooling, video, reports or test parts. In complex builds, it could include a live demo with the customer onsite or watching via computer link. Since a successful engineering study will reduce risk and increase the probability of a successful installation, it is worth the cost and time to have an engineering study completed.

Non-Disclosure and Intellectual Property (IP)
One of the most important aspects of the specification document may include who owns any intellectual property that comes out of the engineering study and integration build. It is important for the company to obtain a non-disclosure agreement (NDA) and determine who will own the intellectual property (IP) from any engineering study or integration.

Generally, if the client is paying for the engineering study, it will include any parts or technology that is developed in the course of the study, and therefore it will be the property of the client.

In other instances, the integrator may be interested in some aspect of the design that is being created as part of the engineering study (for example, it is a new part or aspect of a vision system that would be beneficial to other clients) and therefore the integrator or supplier could offer a lower cost in exchange for the intellectual property rights of the component.

Health and Safety Risks
An integration install that is halted because no one thought to involve the health and safety engineer is the stuff of nightmares, so it’s always best to involve them early in the project. There are many safety modifications that can be simply and safely added to a design build, such as light curtains, barriers, sensors or rails, but it is easier to incorporate them into the design, rather than to have to hold up the installation while components are modified or moved to accommodate safety concerns after the fact.

Project Management
The last, and most important aspect of reducing risk in automation is good project management from the first day. Clear, frequent, and transparent communication is essential for a successful automation project, and all stakeholders in both the integrator and client sides should have the same understanding of what was sold and promised, and what the expected results are.

It’s easier to have one point of contact for each side, and protocols in place for design changes, issues that arise during design, installation, training and testing. If there is an issue, the project manager should be made aware of it immediately, as well as possible solutions or work-arounds, or potential delays.

A relatively new and serious risk that has emerged since the COVID-19 pandemic has been global supply chain challenges. Parts and components that pre-pandemic would have been available in 4-6 weeks can now require up to a one year lead-time, and if a supplier or integrator does not have a part on their premises, it could take several months to obtain it. Since many integrators offer replacement parts as part of their services, adding spare parts to an initial order has become more important than in the past.

A good integrator will have a plan, supply alternatives, or suggestions for workarounds. They will also be able to identify to the project manager early on if there will be supply chain issues, and how those issues will impact the timeline for the project. Timely communication and transparency can go a long way to a successful automation project.

Ramsey concluded “You want to partner with an integrator who doesn’t stick their heads in the sand but has a plan and alternatives. Every project is specific and communication is the most important aspect. Reducing net risk will increase the chances of a successful automation project. An integrator who is willing to communicate often and on a deeper level is a partner for success.”

If you want to learn more about how Ehrhardt Automation Systems Inc can assist you with your robotic integration needs, you can contact Chad at info@ehrhardtautomation.com.

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Factory Automation

Justifying Automation in Your Factory

Whether you’re new to automation and robotics, or building on existing automation, making a solid business case is an essential step in the process. However, justification needs to reach beyond finances. Having buy-in from all stakeholders will greatly improve the odds of success for an automation project.

When determining what level of automation is appropriate, it’s important to consider multiple factors, including the following:
• Overall objectives for the automation project
• A complete ROI picture that includes soft costs
• Labor considerations
• Minimizing risk and planning for success

What are the overall objectives for the automation project?
This question used to have a simple, straightforward answer: reduce labor costs. However, today’s automation solutions can support a more complex business strategy while still making sense financially. For example, does the factory need more flexibility? Being able to ramp up and scale back without having to hire and let go of workers can be a powerful driving force to implement automation.
Are there not enough reliable workers available to keep production running? In recent years, the skills gap and labor shortage in manufacturing have become a serious issue. Providing a safe, pleasant work environment is also frequently becoming a factor that feeds in to the human resources part of the equation.

What is the complete ROI picture, including soft costs?
The ROI calculation used to be simple: compare the capital spent now versus labor as an ongoing cost. Regarding initial hard costs, a common benchmark is seeing payback in 2 years or less. This ROI of under 2 years is frequently achievable, but sometimes misses the mark of including non-financial objectives, and including soft costs to encompass the total cost of ownership.

Today’s ROI equation needs to look at the limits to growth and efficiency without automation, as well as the soft costs incurred with automation. Soft costs will include training, and can also include services tied to the automation such as monitoring and data collection and analysis for Internet of Things (IoT) solutions. With IoT monitoring, predictive maintenance can come into play and significantly reduce down time. If automation can increase OEE from 70% to 85%, ROI will be realized even faster.

The good news for training soft costs is that current automation solutions are typically much easier to use than before. Depending on the specific application, automation can even be as simple as an intuitive touch interface, with no programming skills required.
Of course, the initial purchase cost of the machinery is still a primary consideration. However, with new lower cost options such as cobots, taking a first step into the world of automation doesn’t have to be as big of an investment as would have been required a decade ago.

What are the actual labor considerations?
Comparing automation costs to labor costs isn’t so simple any more. As mentioned in the above points, the availability and reliability of labor can’t be taken for granted. If there isn’t enough workforce availability, then automation becomes a necessity, not an option.
With labor shortages, the cost of not automating can be expensive idle time when a machine operator can’t be found to work a shift, resulting in penalties for missed deliveries, and reputational damage. And, understanding the true cost of overseas labor can make that option less attractive compared to implementing automation.

Unexpected safety regulations can also come into play regarding distancing for human workers. If minimizing risk is a priority and one of the main objectives of the automation project, then the ROI equation needs to look at risk scenarios.
Even for companies that have a solid work force in place, retention is still an issue. If increasing employee retention is a priority, then automation can help take over some of the dirty, dangerous jobs. A factory with new technology that offers a safe environment with ongoing investments in training will be more competitive and better able to attract and retain energetic, enthusiastic, reliable workers.

How will you minimize risk and plan for success?
The importance of planning for success in initial projects cannot be overstressed. The best way to get buy-in from management and employees is to demonstrate the benefits of automation in action. Simulations can give a good idea of how the automation will work on the floor, and minimize the risk of surprises. Another risk factor to consider is the turnover process. What happens when the integrator leaves? How easy is it to train personnel on the new equipment and keep it running?

When evaluating success, look beyond the project itself, and see what happens to the people involved. Are they freed up for higher level strategic tasks? Are people showing up for their shifts? Has retention and recruiting been affected? Factors that go beyond operational efficiency are key to the overall success of the implementation.

To learn more about justifying an automation project, contact sales@ehrhardtsolutions.com

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Factory Automation

Common Sense Robotic Automation

Common Sense Robotics

There are many reasons manufacturers consider integrating automation into their processes. One of the first questions that is asked around the table is “Does the ROI on this investment make it all worthwhile?”

Why are we doing this?
There can be multiple drivers in any capital project and this is especially true for automation. Getting to the bottom of the customer’s needs and expectations at the outset is the most important step to starting off on the right foot and focusing the solution in the right direction.
 
Foremost, work to understand the customer’s current process, their expectations for a solution and the human interaction upon completion of the project. Are they trying to eliminate ergonomic or safety issues? For example, are there repetitive tasks or heavy parts that could be causing injury or safety concerns? Are they trying to reduce/eliminate manpower to improve efficiency and reduce costs? Are they attempting to improve consistency in quality results or production rates?

Why a robot and not some other form of automation?


Capital equipment is typically purchased and then depreciated year after year, often long after their usability has become irrelevant. A piece of automation may be used for a single project and never used again.

The flexibility of a robot versus a fixed piece of automation is one of the main drivers manufacturers will invest in robotics. Because of their flexible nature, there are fewer considerations in up front engineering with robots. They can easily adapt to changes in projects or in the scope of a project. Their programmability allows them to pivot to a new line, different location and even a new task. For example, in automotive assembly where models are ever changing, and the parts changing, the robot can be reprogrammed to new part needs. A robot’s redeployability as a capital equipment asset is a very appealing characteristic for the accountants and investors.

How do you reduce risk?

There are lots of proactive steps that can be taken to reduce project risk, both on the side of the manufacturer and the customer. Identifying risks upfront will go a long way to provide a safer solution that meets the customer’s specifications. The discovery and specification phase should ask questions and clearly identify the elements that are priorities for the customer: 

• What are you going to do with the robot and what is the required?
• What cycle time and production rates do you require?
• What are the payload and reach requirements
• If assembly, what accuracy is required? 

Today’s technologies like risk assessment tools and software for modelling concepts and layouts can do things like simulate and verify robot moves and paths. 
If a customer requires a part of a solution that hasn’t been in your repertoire , there could be a place for a reduced level feasibility study. Maybe certain stations have a higher risk because the way we’re proposing is new to both of us. If they’re looking at purchasing multiple stations, that’s when it makes sense to create a prototype that will identify any issues first. Finding problems in engineering is always less costly than finding it in debugging or worse after installation!

How do you decide on a robot manufacturer? 

Most of the large robot manufacturers do a good job providing robots for all the basic applications. A customer may already have a brand preference because they’ve done research or they have a factory full of a particular brand.  It’s important to pay attention to customer experience. Often they want to use the same brand because they know how it works, how to program it, how to debug etc. Even in this case it’s important to emphasize training, as companies tend to short change at this step. 

When choosing a robot, customers will also consider the availability of accessories. 
2d vision has become very robust and 3d vision is continually improving. Most brands have common industrial communication and IO protocols in addition to End of Arm Tooling solutions. Although many custom EOAT are still being fabricated, standard, off the shelf components are great for spares and cut down on design costs.

How important is service and support?
Your automation system and robotics are a significant investment, so the service and support you’re going to get if something’s not working is of prime importance. When your robot or conveyance is down it’s costing you money. Make sure that training, maintenance, and support are more than a detail for your automation suppliers. 

If you would like to hear more about this topic, check out the Robot Industry Podcast where our own Lyle Weaver was interviewed on Common Sense Robotics.

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The Cost Benefit of Automation

Automation savings extend beyond labor costs

Decades ago, manufacturers that were considering using automation compared the cost of automating against the direct cost of labor they’d be replacing. Adding the number of people, shifts, and hours provided a benchmark to use for determining ROI.

That same basic calculation can be used as a starting point today; the benchmark ROI of an automation project now is typically under 24 months.

However, that historical capital expenditure calculation excludes many important factors that should also be considerations:


• Is human labor even available?
• What additional strategic advantages does automation offer?
• What is the total cost and value of ownership?

Using automation to solve the labor shortage in manufacturing
With the current labor shortage in many factories, the benefits of automation extend well beyond basic cost justification. When factories cannot fill open labor positions, they can’t meet production requirements. The need to increase production without recruiting will often drive a company to invest in automation. The costs of not being able to fulfill orders and losing customers has long-reaching implications that extend beyond a basic ROI calculation.
In addition to keeping production running, automation also helps companies attract workers. People who are interested in working in manufacturing are more likely to choose a company that is actively investing in automation and robotics and is poised to be competitive now and in the future. As well, for people looking for security, a company that has recently invested in automation will appear more stable and secure than a company that isn’t modernizing its operations.

Instead of replacing workers with robots, manufacturers are adding robotics and automation and retraining their valuable labor force for positions that include working with collaborative robots and using automation solutions.
Benefiting from the strategic advantages of automation
In addition to using automation to help attract and retain labour, automation offers many other strategic advantages.
Elevating health & safety levels by automating dangerous jobs
Using automation and robotics for dull, dirty, dangerous jobs can help factories develop an impressive safety record. Health & safety levels can be a deciding factor for potential employees, investors, and customers.

In addition to reducing dangerous jobs, robots can also be used for repetitive movements, leaving humans with ergonomic jobs that won’t cause repetitive stress injury.
Increasing scalability and flexibility with automation
When companies first started implementing automation, the cost equation was most favorable for industries like automotive manufacturing with low mix, high volume production needs. Now, with the reduced cost of automation and the availability of collaborative robots, automation makes financial sense for factories that have a wide range of higher mix, lower volume production runs.
With an automated line or automated production cells, manufacturers can be better equipped to take on bigger orders, or to offer a wider range of options.
Raising quality levels using the repeatability and reliability of automation

A properly programmed robot can perform the same movement the same way with a higher degree of accuracy than a human. New vision capabilities give robotics an even higher capacity for quality control and repeatability. Depending on the type of production being done, this high repeatability and quality potential can be exploited to a manufacturer’s advantage. As well, with data collection and management, traceability can also be incorporated into the manufacturing process.

Winning contracts with automation as a competitive edge
If a customer is comparing several manufacturers, and you’re able to offer the quality, reliability and efficiency benefits of using an automated solution, you’ll have an edge over the other factories using older, less reliable systems. The better-equipped factory will seem more likely to be able to deliver in-spec goods on time.
Understanding the total cost and value of ownership

When evaluating the cost of automation, it’s important to consider the manufacturer’s situation: are they in a survive-or-die scenario or are they in a position to invest in longer-term growth? Automation can provide the solution to both of these issues, and both must be considered in order to budget properly.

With too much focus on immediate needs, future growth won’t be supported; but, with too much emphasis on the future, the current financial position of a company can be compromised. It’s important to discuss potential growth plans with an implementer so that the foundation for a future phase of automation can be accommodated while respecting immediate needs and budget constraints.

The planning and implementation process are also important factors to consider. Having an experienced implementation team that can design a robust system, provide the integration needed with other systems, and deliver the system on time is invaluable.
As far as tangible goods that must be accounted for, there is the cost of the new machinery, plus spare parts and maintenance. For tangible value, the decreased cost of rework and rejects should be factored in.
Although it can be tempting to simplify the ROI calculation, to maximize your investment in automation, it’s essential to consider all costs and all value gained over the productive life of an automated solution.

If you are looking to integrate automation in your factory and need some advice, Ehrhardt Automation Systems would like to help. Reach out to one of our talented applications engineers at sales@ehrhardtsolutions.com

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Press Release: Ehrhardt Automation Systems

Press Release: Ehrhardt Automation Systems

Granite City, Illinois July 22, 2019

Ehrhardt Engineered Solutions Rebrands to Ehrhardt Automation Systems adds Industry Expert to Sales Organization.

“I am pleased to announce that as of today Ehrhardt Engineered Solutions has changed its name to Ehrhardt Automation Systems. Our decision to re-brand is driven by the change in our market focus and reflects where we are today as a company” says Jason P. Beatty, President. “The new name honors our founders of this respected 80 year old machine builder while reflecting our current offering as a world-class automation and robot systems integrator.

Rebranding the company is important for our customers and other stakeholders and especially for talent attraction”, said Beatty. “Assembly automation, flexibility and robot integration have become key value drivers for our customers and partners and is one of the reasons that we have also added new bench strength to our sales team. I am also announcing today that we have hired industry veteran Craig Witt to our management team to drive sales and growth within Ehrhardt Automation Systems.

“Craig will join us as our Vice President of Sales. We welcome Craig’s past clients to reach out to him for automation inquiries, sales, service and support needs”, concluded Beatty.

“As a career champion of advanced automation solutions and complex systems sales, I am excited to join Jason Beatty and the management team at Ehrhardt Automation Systems. The automation systems industry is experiencing significant growth and robotic integration is helping our customers increase quality, retain skilled workers and reduce manufacturing costs. I look forward to working with manufacturers and exploring new opportunities in diverse markets for Ehrhardt” said Mr. Witt.

About Ehrhardt Automation Systems:
Ehrhardt Automation Systems is an automation system and robot integrator based in Granite City, Illinois. The company has been building precision automation, custom machines, assembly automation and factory automation systems for over 80 years serving automotive, HVAC, consumer, electronics, medical and nuclear markets.

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Company contact: Craig Witt at 877-386-7856 | email at sales@ehrhardtautomation.com

Press contact: Jim Beretta | Customer Attraction jim@customerattraction.com

Categories
Factory Automation

Design for Manufacturing and Design for Assembly

You’ve got a great new or updated product that you’re rushing to put into production as quickly as possible. While it may be tempting to take shortcuts in the early design phases, make sure that design for manufacturing (DFM) and design for automation (DFA) are included early. 

What are DFM and DFA?

Design for manufacturing often referred to as DFM – the goal of DFM is to ensure that the most cost-effective materials, parts, and processes are used to produce a product.

Design for automation, also referred to as DFA – traditionally, DFA meant design for assembly. Now designing for assembly must also take into considerations for automation. DFA can reduce labor costs, improve quality, and increase consistency in the production process.

Why can’t DFM and DFA be done closer to production? 

The early design stages are when it’s much easier to make changes. Late changes will delay your time to market, cost more, and be more difficult to implement. Including DFM and DFA early and throughout the design process minimizes costs while improving quality and efficiency. Even if you’re redesigning an existing product, it’s worth tearing down the current design and making the best choices for your current manufacturing and automation capabilities. 

How can DFM and DFA minimize costs and speed time to market?

Prevent problems

The earliest choices made about materials and processes are critical.  Either the material or the process can drive decision-making.  If several materials could be used, then look at the production processes for each material. If you want to use an existing production process, then look at the materials that are most compatible with that process. 

Designing for automation includes answering the engineering questions around how you are going to grip the part? What features will make assembly easier, such as chamfers on mating parts. What features will the tooling need? Will your pallet need a left and right considerations, and how will they be error proofed if there is a manual load station. DFA will cover all these special considerations.

Speed production

Designing for automation allows the product to seamlessly move into production without having to start thinking about automation late in the game. What setup is required? How quickly can changeovers be done? By asking these questions at the earliest stages, the overall part design can accommodate faster production and automation tooling design.

+fastening methods, type of adhesive used

+modular design? Applicable to small part assembly?

+automation: tooling

Minimize errors

Make assembly mistake-proof by using tabs, slots, foolproof orientation, colors and other best practices.

Ensure that tolerances are reasonable for the processes being used, and that quality can be checked  easily and frequently.

+DFA: self-locating parts

Maximize yield

With fewer mistakes in assembly, waste can be minimized if not eliminated; which maximizes yield.

Reduce costs

By making choices with manufacturing and automation in mind, you can 

  • actively select common materials and parts to reduce inventory.

DFA- what level of automation makes the most sense? This usually depends on volume and tooling flexibility.

Manufacturers that use DFM – design for manufacturing and DFA design for automation can get to market faster as parts fit together tooling works better and the entire assembly process is smoother.

At Ehrhardt Engineered Solutions we are experts at helping our clients design parts that are easier to feed, pick, place and assemble. Contact us at 877-386-7856 or email us at sales@ehrhardtsolutions.com

Categories
Factory Automation

What is the Cost of Factory Automation

Automation savings extend beyond labor costs


Decades ago, manufacturers that were considering using automation compared the cost of automating against the direct cost of labor they’d be replacing. Adding the number of people, shifts, and hours provided a benchmark to use for determining ROI.

That same basic calculation can be used as a starting point today; the benchmark ROI of an automation project now is typically under 24 months. However, that historical capital expenditure calculation excludes many important factors that should also be considerations:

Is human labor even available?
What additional strategic advantages does automation offer?
What is the total cost and value of ownership?


Using automation to solve the labor shortage in manufacturing
With the current skilled labor shortage in many factories, the benefits of automation extend well beyond basic cost justification. When factories cannot fill open labor positions, they can’t meet production requirements. The need to increase production without recruiting will often drive a company to invest in automation. The costs of not being able to fulfill orders and losing customers has long-reaching implications that extend beyond a basic ROI calculation.

In addition to keeping production running, automation also helps companies attract workers. People who are interested in working in manufacturing are more likely to choose a company that is actively investing in automation and robotics and is poised to be competitive now and in the future. As well, for people looking for security, a company that has recently invested in automation will appear more stable and secure than a company that isn’t modernizing its operations.

Instead of replacing workers with robots, manufacturers are adding robotics and automation and retraining their valuable labor force for positions that include working with collaborative robots and using automation solutions.

Benefiting from the strategic advantages of automation
In addition to using automation to help attract and retain labour, automation offers many other strategic advantages.

Elevating health & safety levels by automating dangerous jobs
Using automation and robotics for dull, dirty, dangerous jobs can help factories develop an impressive safety record. Health & safety levels can be a deciding factor for potential employees, investors, and customers. In addition to reducing dangerous jobs, robots can also be used for repetitive movements, leaving humans with ergonomic jobs that won’t cause repetitive stress injury.

Increasing scalability and flexibility with automation
When companies first started implementing automation, the cost equation was most favorable for industries like automotive manufacturing with low mix, high volume production needs. Now, with the reduced cost of automation and the availability of collaborative robots, automation makes financial sense for factories that have a wide range of higher mix, lower volume production runs.
With an automated line or automated production cells, manufacturers can be better equipped to take on bigger orders, or to offer a wider range of options.

Raising quality levels using the repeatability and reliability of automation
A properly programmed robot can perform the same movement the same way with a higher degree of accuracy than a human. New vision capabilities give robotics an even higher capacity for quality control and repeatability. Depending on the type of production being done, this high repeatability and quality potential can be exploited to a manufacturer’s advantage. As well, with data collection and management, traceability can also be incorporated into the manufacturing process.

Winning contracts with automation as a competitive edge
If a customer is comparing several manufacturers, and you’re able to offer the quality, reliability and efficiency benefits of using an automated solution, you’ll have an edge over the other factories using older, less reliable systems. The better-equipped factory will seem more likely to be able to deliver in-spec goods on time.
Understanding the total cost and value of ownership

When evaluating the cost of automation, it’s important to consider the manufacturer’s situation: are they in a survive-or-die scenario or are they in a position to invest in longer-term growth? Automation can provide the solution to both of these issues, and both must be considered in order to budget properly.

With too much focus on immediate needs, future growth won’t be supported; but, with too much emphasis on the future, the current financial position of a company can be compromised. It’s important to discuss potential growth plans with an implementer so that the foundation for a future phase of automation can be accommodated while respecting immediate needs and budget constraints.

The planning and implementation process are also important factors to consider. Having an experienced implementation team that can design a robust system, provide the integration needed with other systems, and deliver the system on time is invaluable.
As far as tangible goods that must be accounted for, there is the cost of the new machinery, plus spare parts and maintenance. For tangible value, the decreased cost of rework and rejects should be factored in.
Although it can be tempting to simplify the ROI calculation, to maximize your investment in automation, it’s essential to consider all costs and all value gained over the productive life of an automated solution.

Do you need factory automation or a custom machine. Do you need to learn more about using a robot or automation for a specific production process? Contact us at Ehrhardt Engineered Systems at: 877-386-7856 or email us at sales@ehrhardtsolutions.com

Categories
Factory Automation

How Lean Automation Contributes to a Lean Production Process

When we picture automation, it’s often big multi-station systems with feeders, conveyors, and testing all running with little to no manual intervention. Those systems have been maximizing efficiency in industries like automotive for decades. However, high-volume, low-mix automation solutions are not the only option. 

With the advent of technology like collaborative robotics, automation can be implemented as free-standing stations using a lean approach. High-mix, low-volume assembly operations can take advantage of properly designed lean stations to achieve lean manufacturing objectives including reduced waste and improved quality.

Lean automation can offer multiple benefits:

  • Fast implementation
  • Low capital expenditure
  • Reduced waste
  • Quick ramp up
  • Minimal maintenance

Have a lean system up and running quickly

How quickly depends on the specific implementation. First, we need to look at your overall process to find the best opportunity to implement a lean automation system.  We’ll use lean principles to evaluate your process by asking several questions:

  • Does every step add value?
  • Can any steps be removed?
  • Which steps can be improved?
  • Where can waste be reduced?
  • How can inefficiencies be eliminated?

When we’re looking at adding free-standing robots to a manual process, we’ll likely be considering force-limited collaborative robots that move slower than the types of robots used in automotive assembly. The best station for a collaborative robot isn’t necessarily a process that needs to be done quickly.

High-potential opportunities to implement a collaborative robot include processes that are:

  • Repetitive
  • Precise
  • Dangerous

Robot welding systems are a common independent-station application. Note that even though a collaborative-type robot can be used for a dangerous operation like welding, additional appropriate safety guarding must be designed into the system.

Minimize costs with a lean automation system

An experienced robot systems integrator knows how to right-size robots to suit the application. That means you won’t pay extra for a heavy-duty robot to do a task that a lighter robot could accomplish. 

In addition to the robot itself, tooling is another important cost consideration. By choosing a unit that can use existing off-the-shelf components, tooling costs are minimized. 

When using a robot for an assembly operation, parts presentation must be considered. If a complex feeding mechanism will be required, that particular process or end-of-arm tooling may not be ideal.

We’ll look at processes that can use robotic automation with minimal customization and no special end-of-arm tooling or complex parts presentation required. Those constraints will help speed implementation and minimize costs.

Finding ways to use one robot for more than one station is an excellent way to get the most out of an investment in automation. A robot that can easily change end-of-arm tooling can be used for multiple tasks, as long as other requirements such as payload are met. 

Using one robot for more than one task isn’t an approach we would recommend for a high-volume operation. But, for a low-volume operation, moving one unit between two stations is often cost effective. This strategy can even be implemented in phases, with the robot first used in one station as proof of concept.

Improve quality to reduce waste

In addition to the precision inherent in robotic systems, new vision capabilities are making robots an excellent choice to increase quality levels. By increasing the percentage of in-process and finished items that pass quality iinspections, waste can be significantly reduced.

Ramp up right away

With a lean automation system that’s not heavily customized, there is less to test and adjust at both the factory acceptance and site acceptance steps. Training is also simplified. The collaborative robots that are typically used in a lean automation setup are often designed with an easy-to-use interface that requires minimal training. 

Simplify maintenance with a lean design

By implementing a robotic system that uses off-the-shelf components instead of customized tooling, replacement parts are typically readily available. And, specific expertise for the custom machine isn’t necessary to perform standard repairs. Standard repairs should be able to be done by any technician qualified to repair robots from that manufacturer.

Right-sizing automation is critical

A robotic systems integrator with experience implementing lean systems can ensure that the robots specified will provide as many benefits as possible, including low initial investment, minimal customization, fast implementation, and simplified maintenance.

Want to learn more about using a lean automation system for a specific production process? Contact us at Ehrhardt Engineered Systems at: 877-386-7856 or email us at sales@ehrhardtsolutions.com