Basic Considerations

There are a few basic things to consider when thinking about automating...  

Why Do We Automate?

Is the task..

• too difficult?
• too time consuming?
• too boring?

• too much exertion?
• too many resources?

• quicker?
• more accurate?
• more easily integrated with other tasks?

How far do we go?  Should we automate a single task, a series of tasks or a whole production line?

You should consider that a production line can only go as fast as the slowest operation in it.  Often people think that speeding up one process will improve their production capability - only to find that it just leads to a bottleneck somewhere else.

Also consider that much of the diffuculty in automating any task is in accurately positioning/locating/transporting the part that is being worked on.  If the part has to be secured for one operation, often other operations can be performed with little or no more effort.

Some tasks can be semi-automated (where an operator is needed to assist in part of the process) while other tasks are more suited to be fully automated.  Often, the physical transfer of a component from one place to another is overlooked as something that can easily be automated.

What Type Of Automation?

Often, the existing equipment or procedures will dictate how best to go about automating.  For example:

• A product that is individually pressed may be pressed from a coil of material that is automatically fed into the press.
• A part that is manually drilled in 3 separate places may be automatically drilled in all 3 places simultaneously with a multi-spindle drill head.

Sometimes a component that has several different tasks performed on it can have them all done step-by-step with the aid of a jig or nest to accurately locate and transfer it. eg; a rotary indexing table to move a part to a series of stations where various machining can be done.

The type of automation should also be co-ordinated with the available power sources. Tasks can be mechanical, electric, pneumatic, hydraulic, electronic or a combination of these.  Staff who are suitably qualified to install, run and maintain equipment will be necessary so it makes sense to examine whether electricians, fitters, programmers or other specialists are available in-house or would need to be contracted.

Clamping & Workholding

Any automation relies upon the workpiece being held safely and securely.  It must also be accurately positioned.  This can be as simple as a few G clamps, strap clamps or toggle clamps.  In more demanding cases, it may mean pneumatic or hydraulic clamping of a part.  Care should be taken to ensure that the product is always handled safely and efficiently during manufacture.

What Are The Requirements?

How many parts need to be manufactured? (per minute, hour, day, week, month or year - consider future requirements for expanded outputs).

What do the tasks need in terms of accuracy, force, or type of motion?  Will the automated tasks require an operator with particular skills?

Can the cost of automating be justified in a reasonable time? (eg: over a period of a production run, a financial quarter, season or year.)  It is also important to evaluate the benefits of automation in weighing up the cost.  Is the automation achieving increased quality, efficiency in time, efficiency in production costs, savings in labour or OH & S compliance, greater production flexibility or other advantages.  Once the gains are quantified, what is the net value to your company?

Safety

Any thought of automation should consider all aspects of safety right from the beginning.  Compliance with legal, insurance, and workplace health & safety requirements can be difficult and expensive.  New legislation is aimed at making everyone involved in the design, building, purchase, supply, operation and maintenance of machinery legally responsible for safety.

For more information about safety considerations, see our section on Frequently Asked Questions in the Safety section.

For more information about current safety standards for plant and machinery, refer to AS4024.1 "Safeguarding Of Machinery".  For pneumatic clutch operated presses, refer to AS1219 "Power Presses - Safety Requirements" or click here (opens new window - you may have to "allow blocked content" by clicking at the top of the page) for a summary of sections pertaining to pneumatic control.

After working through the above, you should have a fairly good idea of how to tackle automating your task and what you hope to acheive.  

At Lewis Automation, we specialise in helping manufacturing industry with their requirements for clamping, workholding and pneumatic automation. Our range of products include manual & pneumatic clamps, air valves, cylinders & actuators, air service & ancillary equipment, lifting/handling/transfer equipment, automatic drilling, tapping & indexing equipment.  For ideas on what types of components to use, see our products section.