4 steps to implementing machine automation

Manufacturing today often pairs humans with automated machines to boost productivity and improve safety. Image courtesy of EU Automation.

Manufacturing factory floors are becoming stocked with robots and other automation in large numbers. Less highly publicized is the fact that the number of human jobs in North American manufacturing is also on the rise.

As robotics and automation become ubiquitous in manufacturing, human workers must prepare for the influx of such technology. Following are four key steps that manufacturers must take before implementing new automation.

1. Get the layout right

Correct positioning of new equipment is vital for safe, ergonomic, and efficient production.

If the entire floor plan isn’t considered before installing new machinery, it could lead to costly delays and downtime when things go wrong. Whether the new addition is an entirely new assembly line or a single piece of equipment, it is easy to underestimate the impact new machinery can make.

Material flow should be considered as a top priority. Of course, it makes sense to position a new CNC machine or robot near its sequential machines in the production line because this reduces total production time and eliminates any risks caused by transporting material across the shop floor.

While factory floor mapping is no easy feat, plenty of simulation software packages are available for planning layouts before a new machine’s arrival. This simulation enables manufacturers to see the impact of a new machine on a digital version of the shop floor. It means there are no nasty surprises on delivery day or hasty decisions made during the installation process. Using this technology, shops can place the machine in its ideal location from day one.

2. Develop a machine automation culture

The business case for automation is obvious to the workforce: It can increase productivity, take over repetitive tasks, and remove humans from hazardous environments. However, to fully embrace automation, human workers must also see a personal benefit in how the technology will improve their working lives.

In some people’s minds, automated machines imply human redundancy, often fueled by negative media headlines. Therefore, it must be clear that such machinery will make better use of human employees, rather than make them unnecessary.

Remember, human workers are vital in maintaining, implementing, and monitoring such automation, and business owners should make this clear when introducing new machinery.

In some industries, manual machining will always have its place. However, automated CNC machines are stretching the workforce to new levels of knowledge and paving the way for entire new job roles on the factory floor.

For example, learning to set up or program an automated machine frees up staff from the daily grind, allowing them to focus on higher-level issues that affect mass volumes of products, rather than a single unit. Far from being made redundant by automation, staff can be empowered by it.

3. Get the machine automation training right

Part of a balanced workforce is the community of different ages, skills, and ideas found on many shop floors. But this diversity of employees brings different levels of ability to adapt to new automation. While the younger staff may have used similar automated equipment during their training, staff that are used to the familiarity of legacy equipment may feel left behind.

It is vital that training is differentiated for all abilities, without assuming prior knowledge.

A great way to organically build the skills of everyone on the factory floor is to develop a knowledge-sharing ethos. This may require financial incentives for becoming proficient on a certain machine and training others to a high level of competence.

The opportunity to earn more money on the back of new automation also is a great way to show that boosted production and profits can go directly into the pockets of those using the machines. Again, this relates to the personal benefit that human employees can gain from automation.

4. Get the budget right

Implementing new automation on the shop floor doesn’t necessarily mean a complete overhaul of legacy equipment. It is unrealistic to rip out entire production lines and replace them with new machines. Not only would this be extremely expensive, the downtime from implementing a new haul of machines could be detrimental for the business.

It is better to start slow, reap the benefit, and repeat. Target a specific pain point, make an investment, and use the gains of such investment to implement further automation.

However, in the real world, things don’t always go to plan, especially when it comes to machine maintenance.

For instance, what if a legacy machine needs replacing? Is it better to purchase a new, updated model in a bid to continually modernize the factory, or try to find the same or similar equipment to keep processes consistent?

Following the steady, targeted approach of implementing new automation, if it wasn’t on the manager’s plan to update a certain piece of equipment that now needs replacing, it is better to source the same machine. This maintains consistency on the factory floor, meaning businesses won’t be faced with too many trial patches of automation on the factory floor at once.

Fears about sourcing old, obsolete equipment are common. Many manufacturers assume that because a part is no longer manufactured by the OEM, it is impossible to find.

Thankfully, some suppliers still offer legacy motors, PLCs, and CNCs for shops with older machines. This saves time and money in buying and implementing brand-new parts.

Choosing suppliers for old and new parts is one of the most important preparatory steps in investing in new technology. While factory managers are embracing automation, and are putting contingency plans in place for this, the growing job market in North American manufacturing presents an ideal opportunity to see both humans and automated machines work together, to boost efficiency and profits to new, never-before-seen levels.

Jonathan Wilkins is marketing director for EU Automation, www.euautomation.com/us.