sirris manufacturingday2011 flexible-robotising-robo_job
DESCRIPTION
The smart automated loading and unloading of work centers allows for manufacturing of small runs with reduced workforce. Operators spend time on more value-adding activities. Knowledge of robotics is not a prerequisite. A vision on the intelligent transformation towards flexibility and adaptivity of typical Belgian suppliers.TRANSCRIPT
Flexible Robotizing for small and medium
sized runs
Brief introduction Aluro Group company’s
Analyses of the evolution making industry = genesis of RoboJob
List of requirements
Illustration of our results
Q&A
9/05/2011 1Helmut De Roovere
Reception General. IT-infrastructure Accounting & Finance Reporting
Bending Alu-profileswww.bestbend.com
Subcontractor Mechanical partswww.aluro-cnc.com
Equipment insulating profileswww.aluro.com
Aluro-Group companies
Easily automate your CNCwww.robojob.be
9/05/2011 2Helmut De Roovere
9/05/2011 3Helmut De Roovere
Competition on international level
Prices dictated by a global market
Benefits & Handicaps when producing in Belgium
….
Our customers work in International markets
9/05/2011 4Helmut De Roovere
Small variations by the end consumers lead to amplified variations every step downwards the supply chain
Industry 2011 = Supply chain
Production companies must be SUPER flexible, smaller lotsizes, rapid manufacturing of prototypes, shorter lead times, ….
9/05/2011 5Helmut De Roovere
Internal capacity mechanical parts
Market demand
Time
Overtime, weekendwork, work during vacation, recruitment, (over-)
investments,…STRESS
Tempory unemployment,dismissals, insolvency,…STRESS
Recources
24h x 360 days = 8640 h
14h x 220 days = 3080 h
Machine capacity
Operator capacity
9/05/2011 6Helmut De Roovere
a glimp at our labour market
Evolution of labour cost in Industry
Gross added value per person Productivity upcoming economies
9/05/2011 7Helmut De Roovere
Schrink of our working population
Evolution of Gross margin
1995
Market tariff CNC work 60,- €/h
Labour cost CNC operator -22,- €/h
Depreciation of CNC machine -12,- €/h
Tooling cost -5,- €/h
Gross margin 21,- €/h
2010
60,- €/h
-38,- €/h
-12,- €/h
-5,- €/h
5,- €/h
• Over a period of 15 years, decline of gross margin by 76% !!!!!!!
• Attempt to compensate this by having one operator servicing more machines
• This is harder & harder to achieve by rapidly changing volumes & rising product flexibility
• Consequences are , increasing pressure on production companies and their workers
• As this tendency is rising, our work environment becomes more & more unappealing ,
• Attempt to maintain gross margin by working longer with machines, or working with only second hand machines
• Doing so is only a temporary solution, on a longer term this is pernicious
9/05/2011 8Helmut De Roovere
Summary of analyse
9/05/2011Helmut De Roovere9
+ Supply chain demand for great product- & volume flexibility
+ Our production output is based & depending on labour
+ Labour is not flexile, expensive and hard to get
+ Our labour population is general declining
+ Our labour cost is too high
+ Our productivity seems to stagger, we’ve reached the limits
+ Our gross margin declined with +70% over the last 15 years
MARKET CHANGEMENTS ARE DRAMATIC
Solution is urgent needed
Our goal at RoboJob
9/05/2011Helmut De Roovere10
2010
Market tariff CNC work 60,- €/h
Labour cost CNC operator -38,- €/h
Depreciation of CNC machine -12,- €/h
Tooling cost -5,- €/h
Gross margin 5,- €/h
30% is set-up related
70% is related to production output
Small & medium lot-sizes
We aim to cut this labour factor
9/05/2011 11Helmut De Roovere
Integrated Robot System-Chuck Work
What we developed …
9/05/2011Helmut De Roovere12
Easy to integrate on existing CNC machines
Usable for a RANGE of products (cfr. Range of CNC)
Compact solution, workspace = limited & expensive
CNC easy accessible for operator
Very short set-up time < 5 minutes for new product
Set-up by CNC operator NOT by Robot programmer
Re-usable on other machines
Re-usable when extending to decentralized automation
Results within normal working hourswhen making small & medium batches
1995
Market tariff CNC 60,- €/h
Labour cost operator 22,- €/h
Depreciation of CNC 12,- €/h
Tooling cost 5,- €/h
Gross margin 21,- €/h
2010
60,- €/h
38,- €/h
12,- €/h
5,- €/h
5,- €/h
2011 + RoboJob
60,- €/h
13,- €/h Only for Set-up
12+6=18,- €/h Additional depreciation
5,- €/h
24,- €/h Back in business !!
9/05/2011 13Helmut De Roovere
In a 2 shift environment; 220 working days x 7,6h per shift= 3344 h per machine per year
30 % of operator time is set-up related = 1003h/year
Remaining time = production time (3344-1003=) 2341
During this production time you can create extra gross margin of (24-5=)19€/h
On a year this is extra gross margin of 44.479,-€ per CNC machine
9/05/2011Helmut De Roovere14
Possible extra results, nights, weekends, NO vacation,…
220 working days x 8 h per night = 1760 u per machine per year 44 workweeks x 2 weekend days x 24 u = 2112 u per machine per year Total additional intrinsic capacity = 3872 u per machine per year This is more than during normal working hours 3344) !!!!
0 €
20,000 €
40,000 €
60,000 €
80,000 €
100,000 €
120,000 €
140,000 €
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Possible additional gross margin
9/05/2011Helmut De Roovere15
An industrial Robot is a durable resource :
The utmost flexible automation component
A proven uptime of 99,99%
A proven life expectancy of + 15 year
IRS-CW system is a durable resource which :
Even by small- & medium sized batches
Can be put at work immediately WITHOUT SPECIFIC ROBOT KNOWLEDGE
Set-up time < 5 minutes for new parts, < 3 minutes for repetitive parts
Disconnect invoice hours from labour hours (70% disconnection by small & medium s.)
Takes away production pressure from operators , this brings peace in your company
Multiply your gross margin by 3 during normal working hours
Immediately makes your potential capacity available in a structural way
Guaranteed pay-back time < 2 years within normal working hours
Potential pay-back time of 6 months
Can be put at work 24h/day , 7 days a week
Works for free after 5 years
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