Robotics for Plant Automation

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5 Νοε 2013 (πριν από 3 χρόνια και 9 μήνες)

51 εμφανίσεις

2012

Northwest Ohio Manufacturing Forum and Expo


Re
-
Shoring America with
Robotics and Flexible
Automation

Who is MCRI

Robot Manufacturers


ABB

FANUC

Kuka


Motoman

Adept

DENSO

Epson

Kawasaki

Nachi

Okura

Reis

Staubli

Save Your Factory


Manufacturing
Paradigm


We
need to off
-
shore
to low
-
cost
labor
markets to be
competative


Facing the challenge to
re
-
shore


What steps can be taken to
enable North American
manufactures to be globally
competitive

Importance of Manufacturing in America



Leads in GDP Growth & Productivity


Leads in Innovation:


70% of Total Private Sector R&D


90% of Patents


U.S. Manufacturers have added 495,000
American jobs since 2010


Workers earn pay and benefits about 17%
higher than other workers


Backbone of Defense Industrial
-
Technology Base

Why Invest in Robotics?


"In world terms three to five million of jobs would not exist if automation
and robotics had not been developed to enable cost effective production
of millions of electronic products, from Phones to
Playstations
."
-

"Positive Impact of Industrial Robots on Employment" by
Metra

Martech

November 2011


robots carry out work in areas that would be unsafe for humans


robots carry out work that would not be economically viable in a high wage
economy


robots carry out work that would be impossible for humans.

Robots Create Jobs:

Robots Improve Work Conditions:

Re
-
Shoring Paradigms


N.A.
-

Higher costs

-

Labor

-

Healthcare

-
Legal

-

Tax Rates

-
Environmental laws


Offshore

-

Low cost labor

Traditional Cost Comparison



Start with the
piece part cost

for a
domestic product


Compare this with the piece part
cost for the same item in China or
India

(It will almost always be
lower)


Add the
cost of freight

to get it to
your customer

Realistic Cost Comparison


1.
Shipping

2.
Inventory

3.
Insurance

4.
Quality

5.
Travel

6.
Vendor Selection

7.
Infrastructure Risk

8.
Material

9.
Labor

10.
Other



Other Considerations


Legal Issues

Theft/Piracy

Cost of additional paperwork

Cost of employee morale

Cultural/Communication difficulties

Loss of manufacturing control and
flexibility

Training
costs

Lead Time, QC, Inventory

Underestimation of startup costs

Increasing labor costs once a vendor
relationship is established

Cost of transition

Cost of layoffs and severance

Cost of inventory carry due to shipping

Cost of managing offshore

Cost of bringing a project back to the
U.S.


Using the North American Option


Offshore

North America


Lean Manufacturing


Robots & Automation


Quality Programs


Just in time Inventory


Capitalize on culture, laws &
standards

The Real Long Term Winner?

Keys to Manufacturing Success



Manufacturing will go to the
countries whose companies


Embrace automation


Use lean manufacturing processes


Reduce production costs while
improving quality


North America is in the best
position to win the race

Case Study

Re
-
shore Packaging Operation


Considerations


Labor cost rising

Quality concerns

Damage during shipping

Inventory regulation

Changing packaging/product



Case Study

Re
-
shore Packaging Operation

Challenges


Running multiple
sku’s

simultaneously

Floor space

Amount of equipment required

Available labor

Throughput

Varying product and production needs

Changing inventory

Maintenance

Ability to grow



Case Study

Re
-
shore Packaging Operation

Packing/
lidding

area

Challenges


Erect 3 sizes of case

Random sizes can be processed

Traffic control

Maintenance

Data acquisition



Case Erecting
Lidding

Development


Case Erecting
Lidding

Development


Case Erecting
Lidding

Development


Installed System


Re
-
Shoring Results


Successes


Flexibility for scheduling

2 operators for packaging

Future automation of RF sealing

Reduced inventory

Total inventory tracking

Data gathering

Remote diagnostics

Local support

Shipping cost

Damaged product

New product additions

Future efficiency

Reliability



Questions and Contact Information


Motion Controls Robotics, Inc.

1500 Walter Ave

Fremont, Ohio 43420



www.motioncontrolsrobotics.com


Tim Ellenberger VP

(419) 334
-
5886