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SUPPLEMENT SUSTAINABILITY IN MANUFACTURING WASTE NOT, WANT NOT Manufacturing
processes often lead to waste. This waste can, however, be minimised by using the right tools, as Mikko Urho, CEO, Visual
Components, explains
A common issue in manufacturing is the incorrect programming of robots used for welding, cutting or spraying, leading to inaccurate task execution. For example, if a welding torch fails to follow a precise 3D arc around a metal workpiece and instead creates an incorrect shape, the material may need to be discarded. However, with robot offline programming (OLP),
MITIGATING WASTE IN THE MANUFACTURING SECTOR
T
he global production and manufacturing sector is responsible for 20% of worldwide carbon emissions and
consumes 54% of global energy resources. As such, it is under significant pressure to mitigate the environmental damage caused. From production line errors to inaccurate robot
movements, manufacturing processes often lead to waste which harms the environment. The manufacturing sector must therefore focus on enhancing efficiency in every factory operation to address waste effectively.
EMBRACING A CHANGE IN MINDSET Waste reduction requires a change in mindset, with employees adopting a lean manufacturing philosophy. Lean manufacturing is focused on ensuring faster processes, greater efficiencies and high levels of consistency across every process in a manufacturing plant. First introduced during the 1900s, it’s a mindset that has stood the test of time. It has been adopted by Toyota, with the automotive manufacturer focusing on making only exactly what it is needed, with the exact amount of materials needed. In the case of any abnormality being detected, production is stopped and is immediately rectified. This eliminates the flow of defective products and any corresponding waste being produced. A ‘Just-In-Time’ philosophy, where the minimum number of parts needed to build a car are stocked in advance, means that the product can be built as soon as the order is received. Waste elimination is at the heart of lean
manufacturing, and simulation software can play a key role in bringing it to life. Take, for instance, a planned component machining system. A 3D simulation of the system can fully replicate its processes, allowing users to check whether robots and items can both move successfully and accurately complete their individual jobs. It allows any potential bottlenecks that could delay production to be identified and fixed. It can even enable manufacturers to identify and remove any unnecessary pieces of equipment from the production process. This approach empowers manufacturers to reduce waste by ridding themselves of surplus materials, equipment and the costs involved with the original outlay. Reducing waste also extends to the time spent on specific tasks. For example, there could be numerous AGVs on the factory floor transporting heavy materials between areas, but are they following the quickest route? Simulation software can assist in planning the fastest and most efficient paths for these AGVs. This ensures materials reach their destinations more quickly, allowing products to be built in a shorter timeframe.
HIGH ACCURACY AND REPEATABILITY IN ROBOT TASKS Production errors are a major source of waste, impacting materials, time and money.
30 DESIGN SOLUTIONS - SUPPLEMENT JULY/AUGUST 2024
factory employees can simulate the robot and its work cell in a digital environment. Movements and workflows can be tested virtually before being implemented physically. This allows for full validation and testing of every intricate detail. Consequently, manufacturers can effectively utilise robotic solutions, benefiting from highly accurate and consistently repeatable processes.
FUTUREPROOFED WASTE MANAGEMENT Reducing waste in manufacturing is crucial for both environmental sustainability and operational efficiency. Implementing lean manufacturing principles and advanced technologies like simulation software and offline programming (OLP) allows manufacturers to minimise errors, optimise processes and eliminate unnecessary resources. These approaches promote a culture of precision and sustainability, scrutinising every aspect of production for potential waste. As industries evolve and improve their
practices, their collective efforts to lessen environmental impact will greatly contribute to a sustainable future. Adopting these changes addresses current challenges and paves the way for long-term success and social responsibility.
Visual Components
www.visualcomponents.com
Manufacturing processes often lead to waste which harms the environment
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