W H A T T O D OBEFORE YOU AUTOMATE

PATRICK | FACTORYFIX .COM

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In your manufacturing facility, maintaininga streamlined production process isimportant. Whether you’re engaged inassembly, manufacturing or distribution,you have the opportunity to automate everyprocess step with well-thought-outindustrial robotics solutions. Industrialrobots are an investment that need to benurtured, and should not be purchased on awhim.

With a successful installation, your factorycan expect optimized tasks, reducedvariable labor costs, and less workman’scomp issues. While industrial robots areincredible versatile tools, making the wrongvendor selection can hinder your processesand limit overall flexibility. It’s important tounderstand the various liabilities, safetymeasures, features and benefits ofindustrial robotics before purchasing one.Check out the guide below and secure yourinvestment by putting in the work beforeyou start...

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1 : WHAT DO YOUWANT TO AUTOMATE?

The absolute first step to buying anindustrial robot system is to choose whatprocess you would like to automate. Youprobably already have a bunch of ideas asto what processes you would like to haveautomated. I am afraid to say that most ofthe tasks you thought were goodcandidates for automation are probably notthe best choices to begin with. We need tobe realistic about what the technology cando today. Some applications are easier toautomate than others and as a firstintegration you should start small andsimple.

Ideal tasks for your first robot system aretasks that are highly predictable andrepeatable.

Tasks that are highly repetitive, predictableand structured are the easiest to automatewith a collaborative robot.

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Easy to Automate:

Part presentation

Part drop-off

Harder to Automate

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Complex logic or decision-makingSensorsVisionForce-torque sensor

Always dropped in the same place

Little part changeover or changeover among similar partsAlways picked in the same placeOrdered parts and workpiecesIf many parts, structured in a matrix ortray

Repetitive tasks not requiring the robotto apply forcePick and placeDispensing

Parts

Part presentation

Force controlled processes

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GrindingPolishingDrillingFine assemblyProcesses requiring specialized tools or human know-howWeldingPainting

Moving conveyorsUnstructured presentation (bins)Integrating communication with other machines

High changeover rates of parts withdivergent properties (size, shape)Deformable parts

So what should be included in a customquote from a robot integrator? It is your jobin this stage to eliminate the “risk factor”that integrators build into their quote if allthe factors of a project are not 100% clear.I’ve seen a lot of projects go wrong becausethis initial step was not followed. The bestthing to do is to write out a formal RFQdocument. I’m not talking about page andpages of T’s & C’s, just a simple one pagedocument that lays out the following items:

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What products are being handled in thesystem? What is the weight? What type of material?What is the desired cycle time?What other machines are going to beinvolved in the system?Where will the system be installed?

Getting all this down on paper makes itsuper clear for the integrators quoting thejob. This allows them to sharpen theirpencil and give you their best price. If youget three prices that are way out of whack,it probably means that your RFQ is not asclear as it should be.

3 : SET CLEAR RUN-OFF EXPECTATIONSAND NEGOTIATEPAYMENT TERMSNext, you’ll need to determine the viabilityof your selected equipment. It’s importantto be confident that your purchasedequipment can meet project standards,meet changing goals and fully automateprojects. Not all industrial robot systemsare created equal. If this is your first robotsystem, it’s best to start with a simpleapplication. During the pre-purchase phase,establish your automation path clearly.To do so, set clear and measurableacceptance metrics for the system run-off.Make sure the integrator meets thesetargets before you accept the system andrelease the final progress payment to them.And speaking of payments, you need tonegotiate a progress payment structurewith your robot integrator.

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The industry standard is 30% downpayment with the purchase order, 30% atdesign review, 30% on successful run-off atthe integrator’s facility, and the final 10% isusually paid 30 days after the system isinstalled at your facility. Obviously thesecheckpoints can be tweaked, but you wantto keep it fair for both sides so that yourintegrator does not run into a cash-crunchthat delays them from ordering anymaterials needed to complete your project.

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4 : WHICHINTEGRATOR IS THERIGHT FIT?Your industrial robot, in all likelihood, willbecome one of the main focuses of yourfactory floor. For this reason, it’s highlyimportant that you keep it running day inand day out. While industrial robots areincredibly reliable, it is a mechanical deviceso it’s inevitable that you’ll need supportand annual preventive maintenance.

Does your vendor offer on-site support?Are they well-connected and familiarwith the robot’s manufacturer?How quickly can support personnelbecome available?Does your vendor offer spare parts?

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An integrator’s ability to provide timelyservice should be a major considerationwhen purchasing your industrial robotsystem.

Your vendor can’t be only a vendor. Even ifyour company has comprehensiveresources and maintenance staffavailability, issues will most likely pop upthat can only be resolved by your integratoror other industrial robot expert. Beforesettling on a robot integrator, consider thefollowing questions:

If your provider offers can honestly answeryes to the above questions, they’re likely acredible provider. You should considercompany size, too. Large robot integratorfocus on winning large projects, so youneed to make sure the company size of

5 : COMMIT TOPROPER PREVENTIVEMAINTENANCEEvery robot needs preventive maintenanceto ensure top-level performance andconsistency on the production line. Whenrobots do not have regular preventativemaintenance checks performed, it cancause parts and components to break downor malfunction, which can cause aslowdown or shutdown of your production.Industrial robots that are properlymaintained can last for many years, evendecades, before needing to be replaced.

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your robot integrator matches the size andcomplexity of your project. If you’ve hired alarge integrator to do a simple and smallproject, you’re likely paying too much. Onthe flip-side, you can get in trouble if youhire a small integrator to do a large andcomplex system. These companies can getin over their heads and do not have theresources to properly support your system.

Backing up the controller memoryMonitor robot in regular motion,inspecting robot, harness and cablesInspection of brake operationCheck robot repeatabilityListen for excessive audible vibration andnoiseGrease joints, according to specific robotmanual (or analyze grease if alreadyperformed)Visual inspection of teach pendant andcontroller cablesCheck cable connections, cooling fans,power supplies, safety equipment, andother equipment for functionalityTest and replace RAM and APC batteries.

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By keeping a regular preventativemaintenance schedule, you are extendingthe life of your robot exponentially.

While planned maintenance may shutdown production for a short time, it isnothing compared to the production timeyou may lose if your robot stops working.What gets done during annual preventivemaintenance appointments? Here are someprocedures suggested by major robotmanufacturers:

6 : COMMIT TOSAFETY STANDARDSYou should examine the many rules andintricate regulations surroundingworkplace safety standards. In fact, allparties associated with robotic automationprojects need to adhere closely with thesestandards. In every case, your workplace’sdecision makers will need to providenecessary training to secure the safe use ofcell operations, maintenance, check-ups,installations and prolonged use.Installation should be handled inaccordance with a manufacturer’srecommendations as well as conformanceto industry standards. Any of yourworkplace’s temporary safeguardingdevices, practices or installation supportsshould be implemented to minimize any

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If any further action is required and therobot needs repairs, the technician shouldreport the issues so arrangement can bemade to make the needed repairs.

Physical facilitiesInstallation specificationsElectrical facilitiesIdentification requirementsPeripheral equipment action andintegrationEmergency stop processes andrequirementsSpecial robot operaqting conditions

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workplace hazards associated with newequipment installation. Above all, coveryour state’s safety standards regarding thefollowing areas:

Your education of safety standards shouldsimilarly include in-depth risk assessmentcoverage. Any safeguarding devices shouldbe similarly regarded in worker awareness.Operational safeguards, awareness devices,safety training and in-depth repairguidelines, too, should be included.

Examine the United States Department ofLabor’s Section on Industrial Robots andRobot System Safety to streamline yourworkplace’s safety education.

7 : HOW YOU CANEXPAND YOURROBOT SYSTEMThe future of industrial robotics is bright,and integration possibilities are continuingto expand. Robot systems can be incrediblysimple—such as a simple pick-and-placesystem. But they can also become fullyintegrated systems performing secondaryoperations that deliver even more return oninvestment.I always suggest that your first roboticautomation system should be as simple aspossible. Keep it to an application that isconsistent and ideally involves only onetype of product. Once you introducedifferent products into the system, thesystem demands multiple programs andadditional peripheral equipment that

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workplace hazards associated with newequipment installation. Above all, coveryour state’s safety standards regarding thefollowing areas:

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needs to identify which part is being run atthat particular time.

Now that you have a simple industrial robotsystem running in your facility. You canstart to look at ways to expand upon thatsystem. For example, if you have a robotdoing machine tending on one of your CNCmachines, it might be a good idea to addan automated part inspection station. Thiscan be a rather simple upgrade for anintegrator, but only if the initial designaccommodates it. It is always a good ideato think about future plans before youpurchase your initial robot system.