Industry Focus Automotive Supply Chain A cure for automotive headaches
The UK automotive industry has undergone something of a transformation in the last few years. Manufacturers have once again started to invest in creating localised supply chains providing them with fast access to the many components needed in their vehicle assembly operations. Here, Mike Wilson of ABB Robotics UK and Ireland, looks at how some of the common headaches faced by the UK’s Tier One automotive companies could be alleviated through robotic automation
T
he UK car industry is one of this country’s biggest manufacturing success stories, and a lot of this success is due to the industry’s extensive use of automation, including robots, which are used to handle a wide variety of processes spanning everything from welding through to painting and handling.
This success is having a knock-on effect on the supply chain, which is enjoying a renewed lease of life as cus- tomers have come to realise the cost, time and quality benefits of sourcing components locally rather than from overseas. By itself, the UK automotive supply chain generates around £4.5- £5bn of added value to the UK econ- omy each year. According to the Society of Motor Manufacturers and Traders (SMMT), around 2,350 compa- nies identify themselves as suppliers to automotive companies, with around 25% describing themselves as Tier One. Whilst being a Tier One supplier is a prestigious position, it is also a demanding one. As the final feed-in for assembled components to the main automotive OEMs, Tier One suppliers have little room for error in their processes. Whether supplying a body panel, drive train assembly, car seat or even a small metal bracket, a Tier One supplier must ensure their product is delivered on time, in the right quantity and to the right specification.
Curing the headaches
When it comes to the use of robotic automation in Tier One processes, the old saying ‘what’s good for the goose is good for the gander’ is particularly appropriate. Robots have played a major role in helping the automotive OEMs to achieve world leading stan- dards of efficiency and productivity whilst dramatically reducing product wastage. As such, robotic automation presents an equally valid solution for the automotive supply chain too. Today’s robots offer high production up-time, virtually eliminating the risk of disruption due to failure. Developments in diagnostics technol- ogy, including ABB’s own Remote Service technology, also mean it is now much easier for operators to iden-
Automation OCTOBER 2013
photographing the target - highly useful for inspecting welds and parts of the target that cannot be reached with a static camera.
A 300Kb bitmap image is uploaded to the PC hard drive at each inspec- tion position. The uploaded image can be readily identified by a file number linked to the part number or product bar coding. If necessary the stored data can be transferred to a central server.
tify and pinpoint potential problems before they can escalate.
This brings particular benefits in the interlinked production processes typi- cally employed by Tier One compa- nies, reducing the risk of stoppages that can cause disruption and delay further down the line.
Developments in vision technology have opened up new possibilities for product inspection applications. Cameras linked to the robot arm enable any flaws to be traced before they can pass to the next stage of pro- duction. This brings particular bene- fits compared to traditional inspection practices, where samples are removed from the line and subjected to scrutiny. In contrast, a robot-based inspection system can carry out inline inspection of every part.
Robotic inspection technology can help to greatly reduce waste, time and cost by ensuring that defective parts are removed from the line as early as possible.
This same technology is also helping to overcome issues with the quality of assembled products. A new develop- ment uses an integrated inspection system combining a ceiling, wall or floor mounted robot with a camera, PLC and PC-based archiving software. Using the 6-axis mobility of the robot, the camera can be positioned at the optimum angle for illuminating and
Above: as a
manufacturer and supplier of robotic automation equipment and services with thousands of robot installations
worldwide, ABB is well placed to advise automotive Tier One
manufacturing companies on the best way to optimise their processes using robots
The system can be adapted to handle virtually any type of visual inspection by simply amending the robot and PLC programs. In addition, a modified part can be rapidly brought online, by ‘teaching’ the robot and PLC the new coordinates that need to be checked. Similarly, when new assem- blies are introduced, the robot-based inspection system can be quickly and economically re-programmed.
Just in time processes
The inherent benefits of robotic automation are ideally matched to the requirements of just in time processes. Where a robot is linked to a control system or PLC, parts can effectively be identified and counted, making it possible to see whether there will be sufficient components available for the duration of the pro- duction run.
Further improvements are achieved by the ability of robots to minimise wastage through reduced breakages or incorrect handling. This can help ensure that parts are not unnecessarily lost from the process, enabling operators to count on having exactly what they need throughout production.
Currently around 80% of the com- ponents used by UK motor manufac- turers in the assembly of their vehicles are purchased from UK sup- pliers. This figure is likely to rise fur- ther as companies look to realise the benefits of purchasing the remaining components locally rather than importing them from overseas.
ABB
www.abb.com T: 01908 350 300
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