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The Transition to Flexible Automation By Kristi Schilloff, Channel Marketing Manager, Universal Instruments Corp. I
f implemented correctly, automation can help a company scale its demand requirements, reduce and fix production costs, improve quali-
ty, eliminate health and safety issues, and most importantly, realize a more substantial ROI faster and more efficiently. Automation is the use of various control sys-
tems for operating equipment such as machinery, processes in factories, steering and stabilization of ships and aircraft, and many other applications with minimal or reduced human intervention. Some processes have been completely automated. The biggest benefit of automation is that it saves labor; however, it is also used to save energy and materials and to improve quality, accuracy and precision.
Methods of Automation There are a variety of ways to automate pro-
duction, including mechanical, hydraulic, pneu- matic, electronic devices, and computers — usually in some combination. Complicated systems, such as today’s factories, airplanes and ships typically use a mix of these technologies. Computers control almost all forms of
automation. This began in the 1980s when they were used to control certain facets of the manufac- turing industry. Today, Computer Integrated Manufacturing
(CIM) is at the forefront of automation, controlling virtually the entire process of creating a compo- nent, from design and engineering to the forming or casting, as well as CNC machining. The vast majority of PCBs used in electronics
manufacturing are assembled using automated machines, typically either an SMT or through-hole placement machine. These machines can populate boards with components at extreme speeds and at very high accuracy — something that would be impossible for a human to do. In addition to high-accuracy and speed-driv-
en processes, many other tasks that were tradi- tionally carried out by humans are now being per- formed more effectively by robots, with one robot typically replacing many workers. They are preva- lent in the automobile industry where they are used for welding and spray painting, as well as final assembly at various work stations. In this industry, the need for automation is being further driven by the “smart” automobile and by the advanced technologies and electronics going into virtually every part of a vehicle today. There are specific global market drivers that
are challenging the “tried and true” production models of manual assembly or dedicated automa- tion in favor of flexible automation solutions. These include rising labor costs and a shortage of skilled labor, increased product complexity and shortened product life cycles. Within each electronics assembly market, the
negative impact of these drivers can be mitigated by implementing an agile, adaptable production model built around flexible automation, which is defined as the ability for a robot or system to be quickly and easily re-tasked to change product design for both low- and high-mix manufacturing.
UIC’s Uflex flexible automation platform.
unprecedented numbers and types of advanced gadgets. Be it the GPS system or entertainment sys- tems, everything is moving towards the Internet of Things (IoT) model and this is driving the global market for automotive devices. According to Transparency Market Research, electronic components currently make up more than 30 percent of the production cost of an automo- bile, and that market is estimated to be worth $18.5 billion in 2018. Connectivity is a must for
leading-edge products designed to entice the consumer, and smart cars are the new rage among automotive manufacturers. Just a few years ago, it was only the high-end brands that provided connections for smart- phones and tablets. Now, this is a standard option on most new cars, as is the integration of IoT devices (Bluetooth, web, voice command, automotive infotainment, driver assist technology, etc.). However, putting all of this technology in so many cars and meeting such large production demands would be impossible if these various components were assembled by hand. This is the reason for automotive manufacturers’ greater dependence on automation in their factories. By having robots assemble these high-tech devices with humans assisting, rather than the other way around, manufacturers can ensure repeatable processes, higher-quality products and higher vol- ume productivity.
Automotive Electronics In the automotive industry, continuous tech-
nological developments have totally transformed the driving experience. Cars are equipped with
Using production robots also safeguards
humans from being exposed to harsh chemicals or suffering workplace injuries from repetitive and dangerous tasks. Automation is being used in some way to
build a wide range of automotive technologies. These include parts of the powertrain: transmis- sion, electronic control units and engine control systems; dashboard meters and controls; infotain- ment systems; lighting, which includes LED, xenon and halogen lamps, as well as front- and back-end tail lighting systems; inverters/chargers; and safety-related driver assist technology. These advancements are redefining not just
how cars are used, but also the relationship between a car and its driver. Ultimately, today’s connected car technology is paving the way for tomorrow’s fully-autonomous vehicles. Without automation, this would not be possible.
Consumer Electronics Consumer electronics manufacturers have a
relatively short product run rate of 6 to 12 months. Due to this shortened product life cycle, flexible automation provides a responsive and practical foundation to meet the challenges of fast-changing products and diversity. In the past, consumer electronics manufactur-
ers would purchase customized automation equip- ment for each new product or application on an as- needed basis, which is defined as “fixed automation.” In this scenario, the manufacturer would typically spend upwards of $150,000 for a single automation cell with custom tooling and fixtures designed specif- ically for one function, without thinking about its future limitations. After that assembly’s life cycle,
Flexible automation platforms, such as Uflex, can provide substantial labor and cost savings.
the automation equipment would go into storage until there was an opportunity to repurpose it, which did not happen very often. When these opportunities did arise, the manufacturer would then need to find additional floor space, buy custom tooling (at signifi- cant additional cost), and allocate considerable time for integration and programming, burdening the customer with substantial lead times.
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