FEATURE Robotics
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Strengthening the automotive supply chain with robots
By Julian Ware, UK & Ireland Sales Manager, ABB Robotics
T
he phrase “supply chain disruption” was on everyone’s lips in the immediate aftermath of the pandemic shutdowns. With its complex global network of third-party suppliers, the automotive sector was badly aff ected, with aftershocks still felt today. According to the Society of Motor Manufacturers and Traders (SMMT), September 2022 saw a 6% decline in UK car production following four months of growth, with output again being restricted by “severe supply chain issues”. The situation is particularly acute for EV manufacturers, who face market uncertainties caused by consumer confi dence, shifting government policies and the slow rollout of an extensive, nationwide, charging infrastructure. These types of risks have encouraged manufacturers to support local supply chains, which can provide them with faster and more secure access to the many components vital for their vehicle assembly operations. They are also looking for more fl exible production technologies that allow them to be more responsive as legislation and consumer demand change and electric vehicles replace petrol- and diesel-powered transport. Currently, around 2,350 companies identify themselves as suppliers to automotive companies, with around 25% describing themselves as Tier One. As major providers to vehicle OEMs, Tier- One suppliers have virtually no room for error, with each Tier-One company eager to ensure they deliver their product on time, in the right quantity and to the right specifi cation. With robotic automation already widely used by automotive OEMs, their suppliers are also increasingly turning to robots to improve productivity. Robotic automation also makes it more viable to on-shore or near-shore more links in the supply chain, removing some supply-chain uncertainty. As well as cutting the costs and pollution inherent in transport, robots also off er the inherent adaptability that unpredictable market conditions demand.
18 November 2023 | Automation
Reliability and consistent quality One of the goals of production managers is to identify possible production disruptions before they occur. Today’s robots off er diagnostics that slash the risk of disruption owing to failure. These solutions, which include ABB’s Remote Service technology, are especially helpful in inter-linked production processes that are part of a Just-In-Time supply chain by reducing the risk of stoppages to other stages of the production line.
Achieving accurate quality inspection without taking excessive periods of time to inspect components is another major requirement. Recent developments have seen robots use vision technology for offl ine product inspection. An example here is our 3D vision offl ine quality and metrology cell, 3DQI. Ten times faster than Coordinated Measuring Machine systems, the 3DQI can detect defects of less than half the width of a human hair. This cuts out time-consuming manual inspection, whilst reducing faults and errors. The result is greater productivity and reduced risk of costly and reputation-damaging product recalls.
Accurate assembly
In the past, a major challenge was the automation of assembly tasks in lines featuring continuous movement. Today, new functionality automates assembly applications involving moving car bodies, allowing robotic solutions to be
deployed without the need to make radical alterations to the production layout. This challenge is now being addressed by solutions like ABB’s Dynamic Assembly Pack. Combining real-time vision cameras on the robot gripper and arms with integrated force control sensors, the robot can precisely track the position of the car body as it enters the workstation, enabling precise automated fi tting of a wide range of components, including seats, dashboards and carpets, through to doors, bumpers and wheels.
Robots also make it easier to manage inventory, contributing to effi cient Just-In- Time processes. By linking robotic systems to control and inventory management systems, parts can be identifi ed, tracked and counted, to plan component numbers for each production run. With their precision and repeatability, robots also help avoid damage and the extra costs incurred through losses and the need to overstock to account for them.
Why now? As sourcing automotive components closer to home becomes more prevalent, Tier- One suppliers will want to ramp up their productivity to meet demand. The ability to deliver a combination of secure supply, increased capacity and consistent quality at the right price will be key. As industry continues to suff er from a chronic shortage of engineers, robotic automation is ready to step up to meet these challenges.
automationmagazine.co.uk
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