25 www.drivesncontrols.com September 2024 AUTOMATION n in order, whether that’s in a nested box, on a conveyor, or in a stack. Also think about part handling and fixturing. Significant costs can end up being channelled into part fixturing – even more so if you are working with a range of parts due to multiple fixtures. A good example of best practice here is to focus on one-way assembly; for example, where parts stack on top of each other to create the complete product or common part features that allow common fixturing. 3. Consider TCO Focusing on the wrong drivers for automation is a major error, but sadly one that we see all too often. Some customers are more focused on fitting an automation system into a defined payback period (often less than two years) instead of looking at the value it will bring to the business over its lifetime. A TCO (total cost of ownership) model is a far better measure. The original purchase price accounts for just 15-25% of the total cost of ownership; the remainder is made up of factors such as maintenance, energy usage, repairs, and even end-of-life costs. Measuring TCO rather than ROI will ensure that you get the right automation system for your business, resulting in real long-term value. 4. Remember the process, not just the consumer It can be tempting when developing a new product to prioritise what’s easiest for the consumer, without realising that this may negatively affect the automation process. A prime example of this is shelf-ready packaging. The current trend in the food production sector for front-facing packaging with tear-off flaps or loose fitting lids allows retailers to restock their shelves quickly and easily. But, this seemingly simple change in packaging design has made it extremely difficult for automation to be exploited for end-of-line palletising, because the loose fitting lids or tear-off flaps are not conducive to staying in place. Therefore, before you make any packaging changes – no matter how seemingly minor – think carefully about how they may impact on your ability to automate, and the effect that this will have on production efficiency, and on labour demand. 5. Talk to automation suppliers Engage with your suppliers as early as possible in the automation process. At Fanuc, we are more than happy to support designers who are starting their journey towards automation and will readily provide guidance on what the process is going to involve. We’ve done this countless times over the years as various sectors have started to embrace automation – from manufacturers of low-cost products to high-value goods; companies in the food industry; and more recently, with manufacturers producing EV batteries for the automotive sector. We have experience across many different applications in a wide range of industries that we are happy to share, and which designers can learn from. 6. Try before you buy Finally, as in many other sectors, some automation suppliers are now starting to offer low-cost/low-risk routes into automation for companies taking their first steps into this area. Robots as a Service (RaaS) is a subscription-based model that allows manufacturers to pay a set fee over a specified period of time, and effectively lease robots for use in their facilities. The limitation of this approach is that it will suit only certain relatively simple applications – such as palletising or some types of welding. The upside is that the robot can be repurposed for multiple types of product – palletising a box of cakes is effectively the same process as palletising a box of dishwasher tables, for instance. Talk to your automation supplier to determine if RaaS could be the right way to meet your needs in the short term. By allowing potential users to test the water and experience the benefits before making an investment, it can represent an affordable route into automation for some first-time users. In conclusion, when designing or upgrading any production line, make sure to consider automation as one of the cornerstones of your project from the outset. And, by working with reputable automation suppliers, you can ensure your manufacturing facility is optimised for success, not just for today, but for years to come. n Robots-as-a-Service is a subscription-based option that allows manufacturers to pay a set fee over an agreed period, effectively leasing their robots. It is particulalrly suitable for relatively simple applications such as palletising.
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