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Machine automation in the context of manufacturing refers to using robotics with specialized, flexible software to handle repetitive, routine tasks.
This could be anything from palletizing, pick and place, packaging, and inspecting parts, to operating CNC machines - the sky’s the limit!
The ultimate goal? To increase productivity and accuracy, and to free up human workers so they can focus on higher-level tasks like programming, maintenance, quality control, and even more emerging job positions.
But we’ll get into that below.
There are quite a few reasons you may want to think long and hard about machine automation for your business, and many are very straightforward.
Here are the major benefits of automating your shop floor:
Automating repetitive, mundane tasks like loading/unloading, sorting, and packaging does more than free up workers; with robots handling the basic work, you can increase throughput significantly, because they work 24/7, non-stop, with no breaks and very low maintenance requirements.
Automated systems significantly reduce variability and human error. Robots are very good at precision, repeatability, and consistency. This results in higher, more uniform quality and overall accuracy.
Also, they can perform real-time quality checks and inspections that go beyond the capabilities of even the most detail-oriented human.
We’re not going to lie: the initial investment may be steep, but the long-term savings are worth it.
Robots don’t require salaries, benefits, or holidays. They also reduce waste, rework, and scrap costs. You’ll be happy to know that most automated systems have an ROI of just 1-3 years. Of course, depending on your business, that timeframe could be even shorter.
Automating dangerous tasks improves safety and health. Robots can handle dangerous jobs like welding, palletizing back-breaking heavy loads, and handling toxic chemicals.
Moreover, this lowers the risk of workplace accidents and injuries.
Modern automation systems are remarkably flexible. Robots and software can be reprogrammed quickly to handle new parts or changes in volume and mix - and not all of them require you to know how to code.
This agility allows you to respond rapidly to shifts in customer demand or market conditions.
To automate your machine shop, you have several options to choose from.
However, your method of choice will depend on your shop's needs, budget, and capabilities, and how far into the automation rabbit hole you want to go into.
Let’s take a look at your options:
Once you’ve decided that machine automation is the way to go, it’s time to put a plan in place.
Here are the steps to a painless, productivity-enhancing process:
Sit down, and spend a few afternoons doing your research on the types of robotics and automation tools that could benefit your specific shop processes.
First, think about what tasks are repetitive, dangerous, or require extreme precision - those are the prime targets for automation.
Carefully and extensively map out how automated equipment and human workers will interact.
If you can integrate automation into existing assembly lines or cells, that will make the most impact. For that, you will have to look into collaborative machine automation options, also called Cobots (short for Collaborative robots).
Additionally, look for ways to minimize wasted movement and excess handling of materials. A well-designed, streamlined workflow will lead to major productivity gains.
Your staff needs to be ready for what’s coming, so help them prepare for working with and monitoring automated systems.
If you’re implementing complex machine automation solutions, give solid consideration to partnering with the companies providing your automation tools for training.
Reduce your employees’ apprehensiveness by informing them about how automation will benefit them. Make an emphasis on safety and removing repetitiveness.
Make sure to address any concerns about job security and be transparent about how roles may evolve.
Baby steps! There’s no need to automate your entire shop floor all at once. Pick a single process or production line to start with, implement it, work out any kinks, and then move on to the next area.
Starting off small allows you to prove the ROI of automation and gain buy-in from stakeholders before making a major investment. You can then build up gradually to get to your productivity goals in the long run.
It may seem daunting to estimate the costs of machine automation, but it really isn’t - or it doesn’t have to be.
Robotics prices vary depending on the number of axes (degrees of freedom), payload capacity, and programming complexity, ranging from just $2,000 to over $100,000.
A typical Six-Axis Welding robot starts at around $50,000 (although some highly advanced models with similar capabilities can go for half the price).
More highly developed robotics with machine vision or collaborative capabilities will be on the higher end of the range, from $75,000 to $150,000.
CNC machines range from $50,000 for a small vertical mill up to $500,000 or more for a high-end, multi-axis lathe. The price depends on the machine size, number of axes, and options like automatic tool changers.
Basic conveyor systems start around $20,000 while AGVs typically range from $50,000 to $100,000 depending on their load capacity and battery life.
In short, machine automation of your shop floor can significantly boost your productivity and profits, while making your workers happier, safer, and focused on higher-level tasks.
Yes, the initial investment can seem steep, but the long-term gains in efficiency, quality, and reduced costs will far outweigh any out-of-pocket expenses.
The results are absolutely worth it.
Interested in bringing machine automation to your own shop floor? RO1 by Standard Bots is the best choice for machine shops large and small:
Speak to our solutions team today to organize a free, 30-day onsite trial and get expert advice on everything you need to deploy your first robot.