APPLICATIONS IN IRELAND FEATURE


TURNKEY AUTOMATION SOLUTION A


When a Limerick-based manufacturer of laboratory diagnostics instruments planned a fully automated production line Horan Automation & Consultancy managed the whole project


leading manufacturer of laboratory diagnostic instruments and


consumables required assistance in the design and implementation of a significant extension to their existing production facility to allow for planned increased production in the future. A complete feasibility study was undertaken to ascertain if the project was viable and if so assist with an application for capital for the project. Should the project be viable and capital approved the successful business would project manage the supply installation and commissioning of all machinery, electrical pneumatic and product services and specify the size and layout of the building required.


STAGE 1: FEASIBILITY STUDY The initial stage of the project, the feasibility study and capital request, was scheduled to be completed in three months. Horan Automation & Consulting carried out an initial evaluation of the equipment that would be needed for a fully automatic production line. A key requirement of the client was that no extra staff would be needed to operate the new line. The outcome of the study was that a 250 square meter extension would be needed to house the automatic production line which would consist of seven machines integrated into one fully automatic production line. Horan presented the findings of the feasibility study complete with costings, a Solid Works model of the new production area showing all the machines


and a report on how the installation would impact on existing production schedules.


STAGE 1: RESULT Following analysis of the feasibility study by the client it was decided that the project was viable and would generate a significant return on their investment. Capital was approved and Horan contracted as the project management company for the automation part of the project. A timeline of 12 months was agreed for the design and implementation of the automated production line.


IS ARTIFICAL INTELLIGENCE THE FUTURE FOR MANUFACTURING? Managing director


STAGE 2: PROJECT DESIGN AND IMPLEMENTATION The first stage of the design was to decide exactly what machines were needed and the layout of them. Following research and discussions with potential suppliers the production line was finalised comprising cap unscrambler, vial unscrambler, filler/capper, labeller, tray erector/filler, shrinkwrapper and product


Gerry Horan


At Horan the future of robots is a given and they help their clients to realise the advantages of automation. The organisation works with many clients including high profile multinationals in the pharmaceutical, manufacturing, medical device and food industries. The types of automation projects commissioned by the engineering team could vary from building bespoke pick and place solutions using robots to designing and implementing a turkey complete line of automated machinery. “Technology and the automation industry moves so quickly that


sometimes international machine suppliers are unaware of the individual needs of certain niche areas of manufacturing,” comments project manager


Horan Automation & Consulting T: 052 9152414 www.horan.ie


Conor Mullally. “Machines are churned out on a production line to serve the majority of the market, sometimes leaving clients with a process that only operates to 80% of its potential. Horan steps in to bring the process to 100% by adding the bespoke automation elements that are not only specific to a client’s industry but specific to an individual client. “We ensure that after we install an automation system or machine we


allow operators and maintenance staff a bedding-in period of six weeks. During this time we make ourselves available to them for training and offer a maintenance service to clients if needed after the project is completed. In addition we only source the best quality equipment for our clients, install and integrate the equipment and systems ourselves and offer 12 months’ customer service assistance. Our machines are CE quality certified to the highest operational and safety standards. “Engineers usually choose to automate a process that is not fit for


humans to perform such as the constant handling of bread straight out of the oven at 200 degrees or moving heavy materials. Robots are recruited to enhance the production process rather than replace human operators. In our experience, if a robot replaces an operator it is because the operator’s job was unsafe.”


/ IRISHMANUFACTURING IRISH MANUFACTURING | AUTUMN 2017 17


Horan produced a detailed user requirement specification for each machine prior to


final agreement on price and delivery


conveyor. A range of potential suppliers was identified for each of the machines. Following detailed discussions four suppliers were selected to supply the complete line between them with Horan specifying and coordinating the interconnection between each machine and the exact responsibilities of each supplier. Horan produced a detailed user requirement specification for each machine prior to final agreement on price and delivery. During design and construction of each machine Horan liaised closely with each supplier to ensure that the machines were constructed to meet its client’s distinct requirements and where possible that similar component was used in the construction. This reduces both the amount of training for staff and the variety of spare parts that need to be held in stock. Following completion of acceptance test prior to approving payment and agreeing to shipping to our client. Horan supervised the installation and commissioning by each supplier.


STAGE 2: RESULT The production line which was commissioned on time and within budget has ensured that the client can increase production threefold without increase in staff costs. Horan continues to provide support and training to this client.


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