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WATER & WASTE TREATMENT
Sponsored by
ON A MISSION TO REDUCE WASTE
Mikko Urho, CEO, Visual Components,
discusses the journey towards zero waste in manufacturing
through the use of lean manufacturing techniques and simulation software
W
aste management is a key concern for a number of sectors. It’s true though that specific industries are under greater scrutiny to reduce the impact they’ve had on the globe, including the manufacturing sector. Manufacturing accounts for one-fifth of global carbon emissions, and even more significantly, uses up over half (54%) of the world’s energy sources.
On the manufacturing floor itself, there’s a number of processes that can each have an individual impact on the planet. This could be inaccurate robot movements that create unnecessary waste or other production line errors. However, with the right technology, wastefulness can be avoided.
A cultural shift Waste reduction isn’t just achieved through a set of processes, but via a wholesale cultural shift on the factory floor. Lean manufacturing is a prominent example of this. It’s focused primarily on enabling faster and more efficient processes with optimum consistency.
It’s a strategy which has existed since the 1900s, and popularised by prominent Japanese manufacturer Toyota. The company prides itself on only using the exact amount of materials needed to fulfil specific customer orders. If there’s a fault on the production line, the line is halted and the issue is immediately rectified, preventing the creation of waste from defective products. Lean manufacturing often coincides with a Just-in-Time philosophy, where the minimum number of parts needed to build a car are kept in stock for when an order comes in,
enabling production to begin immediately. Simulation software can play a key role in this mission towards waste reduction. If we look at the example of a planned component machining system, a 3D simulated replica allows users to check whether robots can move sufficiently, enabling them to complete their required tasks. Any other bottlenecks can be discovered and rectified before real production takes place. In a further sustainable move, unnecessary materials or equipment can be removed from production, enabling waste to be reduced and costs to be saved. Waste reduction is also critical in the context of time. If we apply the example of AGVs on the factory floor that carry heavy materials from one place to another, are they following the most efficient path? Simulation software maps out the factory layout and gives users the opportunity to test quicker path routes that can bring materials to their destination quicker and enable faster production of items.
Optimum accuracy and repeatability with robots Production errors can also contribute to waste, and this applies to materials, time and money. For example, if the incorrect programming of a welding, cutting or spraying robot means it is unable to accurately complete its task, this can lead to mistakes. If a welding torch is unable to follow a circular 3D arc around a metal workpiece, with a different shape then created, wasted materials then need to be discarded. This is where robot offline programming (OLP) comes in, where factory staff are able to
46 JULY/AUGUST 2024 | PROCESS & CONTROL
access a digital replica of a robot and its associated work cell. Movements and workflows can be fully refined and tested in this virtual environment before any physical process is initiated. Robotic solutions can then be deployed with reassurance that highly accurate and infinitely repeatable processes will be followed.
Waste reduction can also be achieved in the context of staff actions. Take for example the carbon emissions generated from employees commuting into the factory every day. However, simulation software as well as OLP can be accessed remotely. This gives staff the opportunity to both access and share detailed layout plans while working from home. This reduces individual carbon footprints and helps the organisation to meet its environmental, social and governance (ESG) objectives.
Waste management in the long-term
Reducing waste in manufacturing is crucial for both environmental responsibility and operational efficiency. Implementing lean manufacturing techniques and utilising advanced tools like simulation software and OLP enables manufacturers to reduce errors, streamline processes and eliminate excess resources. These methods promote a culture focused on precision and sustainability, examining every production aspect for waste reduction opportunities.
As industries advance and improve their methods, the shared goal of reducing environmental impact will play a key role in achieving a sustainable future. Adopting these practices addresses current challenges and lays the groundwork for long-term success and accountability.
Visual Components
www.visualcomponents.com
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