Automated production or, in other words, the automated transfer of parts, is always the "leanest" choice if you can cut costs and increase process reliability compared to a manual solution for the same application. But: The savings from automation must offset the higher investment costs. In many situations, a combination of manual workstations linked by automatic systems works better than one or the other. And of course, certain production processes are simply economically "unautomatable" - for example when quantities are too small or the manufacturing product mix changes too frequently.
Efficient transport ensures economical production
Each production process involves moving materials or workpieces from point A to point B. However, as no value is added to the product during transport, investments in this part of the process chain are frequently ruled out in "lean" organizations. This could be a serious mistake: Manual forwarding of parts from station to station, as well as coordination of individual production processes, also represents time and cost. Therefore, the efficiency of a transfer system is a key factor in assessing its economic viability.
Cost comparison of individual systems
Comparing the costs of a manual material transfer system, a "pick & place" solution and an automated transfer system yields important results. For both automated solutions, the comparison assumes a straight-line depreciation over a period of five years and 3500 operating hours per year (two-shift operation). Under these conditions, with a 10kg part weight, the manual solution performs well with cycle times > 35 sec - however, this applies only to low-wage countries. When shorter cycle times are required, automation is the most cost-effective solution.
Automated transfer systems support lean, ensure continuous flow
Indeed, automated transfer can help regulate production cycles, support lean production flow, and ensure continuous production based on customer demand. If you need to accelerate production, automation can reduce transfer and handling time.
Quality can be made more consistent, product surfaces protected, and precision enhanced, due to the stable position of the workpiece on the pallet. And automated transfer lets you transport extremely small, sensitive, or very large products safely. It is also easily integrated into existing, even manual, production lines.
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