DS-APR22-PG48_Layout 1 12/04/2022 11:03 Page 1
INDUSTRY FOCUS AUTOMOTIVE
In control of automatIon In automotIve component productIon
For the workers at Japanese manufacturer G-TEKT, inspecting the steel blanks that form the basis of automotive components and stacking them on pallets was a heavy and challenging task. To help, ABB developed an automated solution for the company…
G
-TEKT is one of Japan’s leading specialists in the manufacture of automotive body and transmission components, with operations
in 12 countries worldwide. The Tochigi plant is one of the company’s main plants for the manufacture of transmission components. The production process involves a 500-ton
press punching out blanks for transmission components from steel sheet. Two workers per shift would visually inspect each punched piece for scratches, dents, and other minor defects. The 42 types of blanks weigh up to 2.3kg and some are over 300mm long – and each person had to load them onto pallets at a rate of about 40 sheets per minute. With the manual handling of steel blanks a
heavy and challenging task, G-TEKT needed an automated solution to carry out the tasks. This, however, needed to fit in a very limited space, while maintaining quality inspection standards and increasing productivity. The company therefore turned to ABB for a solution. For this application, three ABB IRB 360
The ABB PickMaster
3 software is designed to control
multiple robots
It makes full use of the capabilities of all three robots in the system, minimising the number needed and helping save space. “G-TEKT and MES Koshin looked at the unique
characteristics and range of FlexPickers. Together with the PickMaster 3, they have been able to create a system that maximises the capabilities of the ABB robots. We would like to thank G-TEKT and MES Koshin for their efforts,” said Shuichiro Nakajima, head of Robotics & Discrete Automation Business Unit, ABB.
Greater production volumes
Mr. Yoshiaki Ozawa, director, sales manager and production manager at MES Koshin, said: “We used RobotStudio and Picking PowerPac to carry out a
FlexPicker industrial robots were supplied. The system also uses the ABB PickMaster 3 software. Designed to control multiple robots, this system makes the best use of the available space and allows a 10% increase in productivity.
improvinG productivity
G-TEKT wanted to introduce an automation solution that would help improve quality and productivity while shifting workers to less demanding and more creative tasks. System integrator MES Koshin was asked to
lead the implementation of the system. So, the company assessed the needs and challenges of the proposed automated solution, which included limited space for the entire automation system around the press and space constraints limiting the number of robots. G-TEKT also wanted to increase production, going from handling 40 sheets per minute to 50 sheets per minute. Working with ABB, MES Koshin tested
several arrangements of different numbers of robots, before eventually settling on three ABB IRB 360 FlexPickers with a 6kg payload and 1600mm reach. The ABB PickMaster 3 software used for this application is designed to control multiple robots.
4 DESIGN SOLUTIONS APRIL 2022 8
number of simulations to check the feasibility of the system, and finally were able to finish the operation on site and achieve a production volume that even exceeded our expectations.” Commenting on the benefits of the automation
project, Mr Kato said: “Firstly, we were able to automate the work of four workers in two shifts, allowing us to free up these employees to do more creative work. Productivity has increased by around 10%, and we can now produce around 19,200 more sheets per day. From a view of an operator, I believe it’s important that the equipment doesn’t stop, that it doesn’t break down, and that it’s easy to maintain – and they’ve achieved all of these at a very high level.” Looking to the future, Mr Ozawa concluded:
“We have learnt a great deal about the range of tasks that can be carried out by robots to replace people. We look forward to working with ABB to build more equipment and have ideas for a variety of production sites in the future.” ABB will continue to work closely with
MES Koshin to meet their expectations and help G-TEKT realise the next generation of production facilities.
ABB
https://new.abb.com/uk
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58
