Why Automation?

Easy-to-integrate automation technology can significantly increase your production profitability. Let's examine why automation makes sense and how Graco supports automation application in finishing processes. Manufacturing automation is a large and still-growing sector. According to the International Federation of Robotics (IFR), the number of industrial robots sold worldwide is expected to nearly double between 2014 and 2018, reaching approximately 400,000 machines annually. The IFR forecasts that global sales will grow at an average annual rate of 15 percent through 2018, with China—a major regional leader constituting the world's largest and fastest-growing robot market—considered together with other regions. Given sales increases of 56 percent in 2014 compared to 2013, this projection appears reasonable. The automotive and electrical/electronics sectors are expected to continue dominating the industrial robot sector, accounting for 64 percent of the market.

What Are the Key Drivers?

Industrial wireless systems. Wired systems are typically used in industrial network infrastructure because of their ability to transmit high-volume traffic at high transmission rates. However, cables tend to deteriorate over time; transmission quality decreases and maintenance costs increase. When spread across a large manufacturing facility, cables are simply impractical. Growing demand for IoT technologies is driving the implementation of industrial wireless systems and overcoming previous limitations. One limitation was cost; however, wireless sensors and IoT devices are becoming increasingly economical. Another was security; however, advances in cybersecurity are making wireless systems a more viable option.

Connectivity:

Many industries are experiencing strong momentum toward connected technologies such as smart sensors, imaging systems, data analysis software and cloud computing. These form the building blocks of the connected manufacturing facility and smart supply chain. The cost of smart technologies for industrial automation systems is declining, making new technologies more accessible. Integration. Information Technology (IT) and Operational Technology (OT) are increasingly becoming one. Tight integration between factory workers and enterprise business systems improves production efficiency and flexibility, enabling the smart factory. Recently, more than ten leading automation suppliers came together to support OPC Unified Architecture (OPC UA), the most common machine-to-machine (M2M) communication protocol for the interoperability concept developed by the OPC Foundation. This is an important development because it signals the end of industrial automation systems based on incompatible and non-interoperable standards used to communicate between devices.

Analytics:

The increasing availability, affordability and user-friendliness of cloud-based software tools enable manufacturers to obtain advanced process control and optimization, condition monitoring and predictive analytics. These tools allow manufacturers to monitor their production facilities clearly and in real time; they provide the comprehension capability essential for improving decision-making and refining production processes.

Advantages of Automation

Cost:

Automation and robot technology are often thought to be very expensive; however, automation costs decline every year. The initial investment can still be substantial; however, automating a manufacturing process will increase output and reduce costs, providing benefits for years to come. Generally, developing a long-term plan is crucial for manufacturers wanting to achieve significant energy and cost savings. Working with high-energy-efficient existing equipment can provide the highest level of savings; however, opportunities are not limited to this and continue to grow steadily.

Quality:

To remain competitive, manufacturers cannot afford quality differences in their products, particularly when painting is involved. Robots increase quality by ensuring that spray gun parameters and spray motion are exactly the same every time. Even the most skilled applicators cannot provide this level of consistency and precision for each part. Better consistency means less waste; this is detailed in the next section.

Less Waste:

Through precise robot operation, automation can reduce material waste by up to 30 percent. If you use a two-component proportioner such as Graco ProMix PD2K that mixes material close to the gun, waste can be reduced even further. Adding an electrostatic spray gun to the mixture increases transfer efficiency and further reduces material waste.  

Flexibility:

Robots can be easily reprogrammed for a new job. Why create new infrastructure when a robot can adjust settings instantly? This flexibility during transitions saves time and money. Automation also facilitates your production planning, allowing greater flexibility to change materials and colors more frequently.

Labor:

Robots do not go home when their shift ends, and working 24/7 is not a problem for them. In fact, they can do the work of three employees (three shifts of eight hours per day). Therefore, labor and overhead are typically the largest savings factors. Robots can contribute to the workforce in different ways, such as performing repetitive tasks that reduce workplace injuries and job dissatisfaction. Additionally, robots prevent people from doing dangerous work, enabling them to focus on qualified jobs requiring decision-making and reasoning.

Disadvantages of Automation

While automation can increase manufacturing competitiveness, it should not be considered a good solution for every process. For example, there may be a small operation with low production volumes; in this case, the large initial investment in purchasing an automated machine may not be economical. Moreover, in some cases a machine may be less flexible than a worker and may not be suitable for multiple jobs. Emissions must also be considered; different types of machines operate with motors requiring gases or chemicals. The potential increase in unemployment rates as automation volumes increase must also be taken into account. Finally, there may be some unforeseen costs exceeding the production cost savings achieved by automation. Some of these costs may include research and development costs for automating a process, preventive maintenance costs, and training expenses for employees to operate automated machines.

Which Configuration Should Be Selected?

After calculating the automation value in your production line, the next step is to determine the machine configuration best suited to your specific requirements. Basically, there are five industrial automation configurations. A single station can be semi-automatic, automatic or robotic and is primarily used for operations difficult to perform manually or for producing a part requiring several operations. A single station can be simple, low-cost and offer good cycle time; however, it has disadvantages such as automating only a few operations, frequently requiring additional material usage and a high amount of manual work. Continuous machines operate without stopping and move with the workpiece. Continuous machines are suitable for very high volumes and low mix and are mostly used for a specific part. They are durable and quiet but are quite complex, as reflected in their price. Synchronous machines use a mechanism to transfer all workpieces to sequential work stations. They are typically preferred when automating relatively high volumes with little mix or large lot sizes. They provide relatively low cost at high speed and the ability to increase production volume through multiple operations. However, production is limited by the slowest operation in the line. Asynchronous machines use separate work stations that operate independently from other stations in the machine. They are more suitable for higher-mix, lower-volume automation projects; production speed is generally slower than synchronous alternatives. However, production can be increased by using multiple parts per pallet combined with multiple operations. Cycle time is usually longer than the synchronous alternative due to independent work stations, and these machines frequently contain programmable transitions to accommodate high mix. The greatest advantage of asynchronous machines is flexibility; because the equipment is modular, stations can be added, removed or rearranged.   Hybrid industrial automation systems combine synchronous and asynchronous machines. This arrangement combines the high speed, production volume and precise operation characteristics of a synchronous system with the flexibility and high cycle time of an asynchronous system. Disadvantages include typically being the most expensive solution and requiring a large system footprint.

Finishing Automation

Graco offers automated paint systems to increase performance and quality in industries and applications such as wood, aerospace and defense, automotive components, consumer products, cylindrical parts, heavy industry and industrial components. Graco's conventional automatic guns are lightweight, compact and provide continuous spray fans for high-quality finishing. They also include the AL Series Automatic Airless Spray Gun, a high-pressure gun (up to 4000 psi) for working with high-viscosity materials. They can be used at high production rates with many different material types. The AirPro Automatic Air Spray Gun is a low-pressure, versatile gun that works with many different materials and applications. It offers many atomization technology options including HVLP, Conventional and Compatible. The AirPro EFX Automatic Air Spray Gun is a compact and lightweight gun platform for small part applications requiring precise finishing application. Graco's automatic electrostatic guns are designed to deliver high spray performance, efficiency and spray quality. The ProBell Rotating Cup Atomizer uses advanced atomization technology to provide superior finishing quality and transfer efficiency. The Pro Xpc Auto Electrostatic Spray Gun features a low-voltage design for industry-leading safety and various robot integration options. Regarding automatic metering and mixing, Graco technology provides precise and reliable electronic fluid control for a wide range of materials. The guarantee of correct mixing and proportioning ensures that multi-component materials are mixed on demand at the correct ratio for optimal material performance. Precise flow control provides continuous and smooth fluid delivery. The Graco ProMix PD2K Automatic Positive Displacement Metering System provides true volumetric fluid control for precise operation, accuracy and control. In addition to precise and consistent flow control, it offers high accuracy within 1 percent across various materials, pressures and flow rates. Remote mixing is possible for low waste and fast color changes. The Graco ProMix 2KS Automatic Metered Metering System uses high-quality gear counters and metering valves to accurately measure and mix fluids in desired proportions. At the same time, there is an optional closed-loop flow control system to maintain consistent flow rates.

Application Methods

Before deciding to implement a finishing automation system, the groundwork must be properly prepared. This includes reviewing your specific application, properly understanding and mapping the process, and researching and contacting multiple vendors to make correct cost comparisons with your existing production. Short and long-term risks must be clearly defined and continuously mitigated. Deciding on the right time to initiate an automation project and conducting proper planning are important. All advantages must be carefully calculated in terms of cost, quality, delivery and safety. At the same time, risks of not moving to automation, such as increased global competition, healthcare costs, liability and safety, must also be considered. Automation should be approached as a long-term strategic decision and an excellent opportunity to redesign your process and explore your entire value stream. This requires a comprehensive automation strategy. In short, automation is the future of manufacturing. The process of automating has never been so easy and affordable; moreover, it continues to get better.     Marc Gijbels Product Marketing Manager IPD Graco