Industrial Automation And Its Inevitability

production automation industrial automation food automation

Technological progress has helped lift people out of the poverty cycle, raised standards of living and improved the way manufacturing processes were performed. Development in the industrial technology has already made it feasible for manufacturers to achieve the higher level of growth and productivity by adopting smart machines. The increased use of industrial robots is the one indication that automation can produce the finest products in short periods of time. The automotive industry accounts for almost half of the industrial robots sold in Canada. Metal and machinery manufacturing industries come after auto manufacturing.

The impact of automation can also be measured in terms of the number of robots per 10,000 workers or, in other words, robot density. This way of measuring progress suggests that South Korea is leading the chart followed by Japan, Germany, and Canada. The loss of human labor is one of the common fears people express about the growing use of robots. However, the development of novel means of production can only improve the employment situation in a region.

The use of advanced manufacturing tools does not create higher unemployment. On the contrary, it creates job opportunities for skilled labor. Currently, there is a considerable shortage of skilled labor, people who can work with highly sophisticated automated working environments. Despite the unprecedented advancements in automation technology, there are some manufacturing tasks that cannot be performed by machines and that human intervention is inevitable.

The decision to invest in new technologies depends on a number of factors: the cost of machines, competitive pressure, ability to operate and maintain machines, potential benefits, to name a few. Small businesses sometimes cannot afford to go for newly invented manufacturing techniques. Some technologies require years to reach their full potential and become commercially viable. However, there are fully developed and economically viable technologies such as automated welding machines that are within the reach of small metal fabrication shops. Robotic welding systems get the job done quickly and produce great results in terms of precision, speed, and quality. Make sure you are following the trends that will dominate the manufacturing industry in coming years.

Keeping in mind the intensity of competition and demand for high-quality products, automation is the only solution that can help you meet the market requirements. Automated machines will not only increase your productivity but also improve your safety standards. Therefore, stay ahead of the competition and use automation as a solid way to dominate your market.

Related: How to improve productivity and profitability of your manufacturing processes?

BP Automation is an automation engineering company in Edmonton that designs and manufactures automated solutions for various manufacturing processes such as welding, pipe cladding, prototype development, assembling, precision machining, material handling, food processing, metal fabrication, to name a few. We have resources and in-house capabilities to make your complex manufacturing processes lean and highly profitable. Feel free to discuss your manufacturing problems and see how we can help to resolve them.

Various Levels of Shop Floor Automation

Technology has completely changed the way activities are performed on the manufacturing floor. Growth-oriented companies cannot afford to continue with old school techniques following the development and widespread adoption of automation technologies such as welding robots, intelligent machine sensors, and efficient material handling equipment. The advanced manufacturing technology is now within the reach of small and family-owned businesses. You can choose from a broad range of automation solutions that offer everything from material handling and quality control to welding and metal fabrication.

Shop floor automation is a necessity for competitive manufacturing, an environment where it is challenging to meet customers’ expectations. The only solution to keep up with market expectations in a profitable way is to improve operational processes. Bringing innovative automation solutions to your shop floor will help you streamline activities, minimize production cost, and boost profitability. However, you have to choose the type of technology that makes the most sense for your manufacturing processes.

Basic automation solutions

Paper-based systems, where you can only achieve a low level of accuracy and efficiency, is not sufficient when you have to operate with tight margins and intense competition. The basic level of automation can identify gaps in workflow, idle machines, and delays due to stock-outs. By tracking performance and identifying variables that could cause operational inefficiencies, it would be easy to find economically viable automation solutions.

Basic automation tools enable manufacturers to track variables such as order-to-delivery times and cycle times. The tracking ability of this basic system assists manufacturers in areas such as resource planning, logistics tracking, and buying trends. A bar code scanner is a good example of how such a basic technology can bring about big improvements.

Intermediate-level solutions

Intermediate-level automation solutions enable companies to streamline and automate carefully selected manufacturing operations. Sensors are utilized in order to monitor equipment performance. Modern sensors can track down performance degradation and disruptions while improving the efficiency of quality control processes. They enable business managers to track material consumption, scrap rates, and machine run rates for different components.

Advanced automation

Advanced automation level often refers to a fully automated manufacturing environment where robots, sensors, and other machines perform most of the work with great precision and efficiency while maintaining minimal human intervention. In a sophisticated automated environment, machines guide other machines when to take action. Businesses can move gradually from a basic level of automation to more advanced automated solutions depending on their compatibility.

The development of new technologies often stems from experience acquired during the production of a previous series by the same manufacturer. This allows for compatibility with older, in-house, versions of software/hardware solutions. In order to remain competitive in the highly global marketplace, it is crucial for organizations to continually evaluate their current processes and look for opportunities for improvement.

BP Automation offers custom engineering solutions ranging from prototype development and electrical controls to automated pipe cladding and welding in Edmonton and across Canada. Our highly experienced team of in-house engineers has the ability to turn your complex manufacturing problems into simple and affordable automated machines.

Techniques to Improve Welding Profitability and Productivity

Techniques to Improve Welding Profitability and Productivity

Manufacturers often look inconsiderately at welding operations without understanding how productivity can be effectively measured and improved. Successful companies are introducing lean manufacturing to all aspects of their operations, from welding to material handling, nationally and internationally in order to stay profitable in an increasingly competitive environment.

Considering the nature of market competition and demand for quality products, it is hard for companies to survive in the long run without investing in emerging technologies such as robotic welding and automated metal fabrication machines. Many companies do not look at their welding processes from a lean manufacturing standpoint, resulting in the deployment of inefficient welding methods and a drop in profit.

Being a growth-oriented business, you have to analyze your operations carefully and implement the principles of lean manufacturing at all levels of production. Outlined below are some of the techniques that will help you assess and improve the productivity and efficiency of your welding operations:

Ensure effective material handling

Material handling processes cost time and money which means you have to take them seriously and devise a strategy to obtain efficiencies in this area. Delivery of parts to the welding station in a very organized way can decrease welding cost. As compared to the flat position, welding out of position can cost more time and money. If most of your welding operations can be done in an improved position, it is advisable to invest in equipment that could help in this regard.

Operating factor

The second area to study while assessing welding productivity is operating factor or arc-on time. Arc timers and time studies suggest that most of the operators spend only 30-40% of their time in welding. Non-welding tasks such as material handling, cleaning and heating become inevitable (through they’re not important). As a matter of fact 60-70% of the time required to perform non-welding tasks adds no value to the finished products, so it should be drastically reduced, if not completely eliminated.

Improve welding procedure

When looking for techniques to improve the metal fabrication process, examine things such as transfer mode, wire feed speed, travel speed, wire diameter, etc. For example, if a metal fabrication and welding shop is operating with short arc process and a 75/25 blend of shielding gas, shifting to a different gas spray mode of transfer can be more effective.

Add automated or robotic welding machines

The use of advanced manufacturing techniques has become indispensable to environments where repetitive tasks are needed to be performed with great speed and efficiency. Automation is an unprecedented solution to improve productivity and profitability of metal fabrication operations.

Being a leading automation engineering company in Edmonton and across Canada, BP Automation strives to design and manufacture highly efficient and profitable welding and metal fabrication solutions to a wide range of industries. With the help of a brilliant in-house team of engineers, machinist, and electricians, we design automated engineering solutions for panel welding, orbital pipe welding, and sub-arc welding. Consult us if you are looking to embrace the latest innovation in automation technology and implement it into your existing manufacturing system to increase productivity and process efficiency.

The Principles of Material Handling

The Principles of Material Handling

Material handling, a science of loading, moving, packing, storing and unloading of materials, is a critical process in an industrial environment. It is performed either manually or through an automated process. Why is it important to establish and follow material handling principles? Moving heavy objects manually from one place to another can arise a number of safety and health concerns and increase production cost.

A systematic and practical approach towards manufacturing operations not only ensures employees’ safety but also streamlines work. This is why the modern manufacturing industry takes material handling operations seriously and implement automated processes to reduce production cost and time.

Loading, unloading, moving, and other such processes do not add value to the product. Resources spent on material handling, therefore, should be eliminated or at least reduced. What follows are some common material handling principles:

Planning

Thorough planning is essential when it comes to streamlined and profitable manufacturing processes. All material handling activities should be planned. A consultation among managers, suppliers, engineers, consultants, labor, etc. can help you develop a practical material handling plan. Plant layout, location, and storage space should also be considered in the planning process.

Material flow

Material flow can be optimized through equipment arrangement and plant operation sequence. Consider the following steps in the material flow principle:

  • Elimination of obstacles
  • A direct path for material movement
  • Minimum movement between floors
  • Processing of heavy materials close to exit

Automation

Automated handling has become enormously important in the contemporary competitive environment. You should consider the automated material handling equipment to manage the following:

  • Hazardous material
  • Heavy equipment
  • Repetitive movements
  • Large quantities of material

Ergonomics

A growth-oriented manufacturing environment demands from workers the ability to adapt to evolving working conditions. In material handling, the capabilities and limitation of the workforce should be recognized and documented.

System

A coordinated and operational system can be developed by integrating all the material movements and storage activities. The system principle refers to well-integrated and interdependent entities that work coherently.

Work

Work related to material handling (MH) can be minimized without compromising productivity. Businesses should focus more on implementing automated MH operations to reduce manual work.

Safety

Safety conditions in a workplace can directly affect the productivity of workers. Safe MH methods and equipment in accordance with existing safety codes can certainly ensure a safe working environment.

Maintenance

Maintenance is an inseparable component of a healthy production process. A regular inspection and maintenance of MH equipment can save time and money.

Space utilization

Available space in a facility should be utilized in the best possible way. Following are some suggestions in this regard:

  • Reduce temporary storage
  • Stack material by using racks
  • Remove scrap and unnecessary objects regularly
  • Economic order quantities can help reduce inventory

Mechanical handling of materials from inbound raw material to outgoing finished product help reduce production cost and safety concerns. At BP Automation, we design and manufacture automated material handling systems for a broad range of industries. We will help you manage your MH activities in a unified and efficient way so that you can make a good use of your space and resources.

How to Improve Productivity and Profitability of Your Manufacturing Processes?

How to Improve Productivity and Profitability of Your Manufacturing Processes

The contemporary manufacturing industry has to deal with multiple challenges ranging from market pressure to increasingly growing demand for accuracy and precision. Traditional metal fabrication companies, for example, were large operations with hundreds of employees. However, they develop significantly by adopting automation technology and self-purpose equipment such as welding robots, automated material handling and intelligent machines.

Lean manufacturing

The term lean manufacturing refers to a systematic method of waste elimination within a manufacturing process while maintaining the higher level of productivity. The lean management philosophy seeks to implement production processes that achieve precision, high-quality work, safety, and sustainability while reducing production cost and lead times. It focuses largely on eliminating all kind of wastes from all processes. This is what sets lean management apart and makes it very effective.

Waste elimination

Newly developed technologies have always helped companies fix their complex production problems. Lean manufacturing, as a source to achieve sustainable growth, drive companies to develop and implement low-cost improvements into their existing production infrastructure. As mentioned earlier, lean manufacturing is about eliminating all the inefficiencies in forms of waste from a process. Following are some of the major wastes:

  • Unnecessary transportation
  • Waiting time of machines and operators
  • Excess stock of material and equipment
  • Over processing wastes
  • Defects in products

Investing in new technologies

The manufacturing, cutting, and machining industry constantly adopting technological developments promising to make manufacturing floors more efficient than ever. The first step should be to highlight the pain points in your current workflow. Advanced machines such as automated robotic welding and cutting, CNC mills, intelligent sensing devices, etc. can be costly in terms of initial setup and training. However, advanced equipment offers positive long-term effect.

Related: The role of robots in creating more efficient manufacturing operations

Maintenance is essential

Innovative and modern manufacturing solutions can certainly boost productivity. However, automated machines require regular maintenance in order to ensure that they keep working up to expectations. Skilled employees can quickly troubleshoot operational issues and suggest whether or not a machine needs maintenance or repair. You should also consult your equipment manufacturer in order to get technical assistance.

Training and educating employees

Continuously evolving manufacturing technology demands skilled labor. You cannot implement a highly sophisticated production process or technology into your factory or fabrication shop unless you have skilled operators who can run that system. Therefore, it is essential to develop a learning-friendly environment where workers can help you create a more advanced manufacturing process.

Our process

It can be difficult for you to figure out reliable, affordable, and profitable ways to improve the quality of your products and eliminate inefficiencies from your existing manufacturing system. We provide easy-to-understand information, prototype development expertise, and cost-effective automation solutions for helping you to enhance the efficiency, productivity, and profitability of your manufacturing operations. Feel free to schedule a free consultation!

4 Techniques to Safeguard Machinery & Equipment

4 Techniques to Safeguard Machinery & Equipment

The function of safeguarding devices and guards is to protect operators from dangerous moving parts and injuries. Employees working in the general work area should also be adequately protected from flying materials. The use of administrative and engineering controls is the best way to control hazards. Moving machine parts can lead to severe workplace injuries. Following are 4 general methods of safeguarding machinery and equipment:

1. Devices

There are situations where barrier guards are not considered as a practical solution. For instance, a barrier guard cannot be applied to operations where ejection of parts is required. This is where various devices come into play. Some of them are:

Safety control devices

Safety control devices shutdown a machine in emergency situations. Trip rods, two-hand controls, and pressure-sensitive body bars are some of the examples of safety control devices.

Sensing devices

Sensor technology can certainly improve the safety standards of a manufacturing facility. Presence sensing devices shut off a machine when someone enters the danger area.

Physical restraint devices

As the name suggests, physical restraint devices such as a cable or strap limit the movement of an operator so that he cannot reach into the danger area.

2. Guards

There is a variety of guards used to prevent workers from physically reaching into a restricted area. Fixed guards, permanently fixed parts, are used widely to protect workers from the power transmission equipment. It is often recommended to use fixed guards that cannot be removed by operators. Adjustable guards are flexible and can accommodate various sizes of material. There are also self-adjustable guards that allow barriers to open or close depending on the movement of material.

3. Distance

This technique is about positioning the dangerous part of machines in such a way that they are not accessible to the worker during the normal operation of the machine. For example, it can be done by placing the dangerous moving parts against a fence or wall. To implement this technique, it is essential to conduct a thorough hazard analysis.

4. Awareness barriers

Awareness barriers do not provide protection against hazards; rather, they function as a reminder to workers that they are entering into a dangerous area. This is a useful technique but cannot ensure complete safety. Continual exposure to the hazard demands more than just awareness barriers.

It is of utmost importance to develop a safe working environment where employees can work efficiently and with a peace of mind. Machine safeguards not only improve safety conditions but also improve the productivity of workers. Therefore, carry out a thorough evaluation and find out which areas in your manufacturing facility need to be safeguarded.

BP Automation is an automation solution provider renowned for its efficient and cost effective engineering solutions in Canada. We design and manufacture machine safeguards and devices to help manufacturers develop a hazard-free working environment. Consult our engineering team to know more about our automation products and services.

How Machine Safeguarding Can Improve Industrial Safety

Machine-Safeguarding

Hazards are probably an inseparable element of manufacturing processes. Unsafeguarded machinery can result into a variety of health risks ranging from minor cuts or burns to fractures. Machine guards play a key role in improving the safety situation in a facility. It is the prime responsibility of business owners to have their machines adequately safeguarded in order to protect operators and other workers from moving parts, sparks, electric shocks, etc. The blog post will talk about the machine guarding safety and why it is essential to building a safe working environment.

Potential hazards

Mechanical motions and actions create a hazardous working environment where operators have to be extra cautious in order to avoid serious injuries. Lack of confidence in machinery can seriously affect the productivity of workers. Some of the common hazards workers confront during production processes include:

  • Moving machine parts
  • Areas where machines perform cutting, bending, boring, etc.
  • Machines which produce excessive noise
  • Coolants, cutting fluids, chemicals and other harmful substances
  • Exposed and expired electricity wiring

Non-mechanical hazards can also cause serious injuries. Some of them are splashes, flying splinters, debris, etc. Safeguarding machines can eliminate the potential health risks caused by non-mechanical industrial hazards. Minor hazards like dirt can be avoided by wearing appropriate workwear.

Functions of machine guards

A better understanding of how machines work and how guards can protect workers will help manufacturers create a hazard-free environment for employees. The primary function of machine guards is to eliminate the potential risk of injuries. It is also important to make an appropriate use of guards by taking into account the following considerations:

  • Machine safeguarding acts like a barrier between human operators and machines.
  • Firmly attached machine guards would make it difficult for workers to remove them.
  • A safeguard should not act just like another hazard.
  • Guards should not be placed in a way that they block the view of an operator.
  • Safeguards should be replaced if they stop workers from getting the job done efficiently.

The best means of safeguarding are the industrial controls that remove the hazard at the source without relying on the worker’s ability to perform safely. Machine safeguards should be the employer’s’ first choice to fix machine hazards related issues. Personal Protective Equipment (PPE) can help minimize the chances of getting injuries at work. However, PPE has certain limitations when it comes to the hazardous industrial environment.

Modern manufacturing industry relies heavily on efficient yet potentially hazardous equipment. Manufacturers should make sure that their employees are well protected against machine-related injuries. The entire production infrastructure should be taken into account in order to develop the right safety solutions.

BP Automation offers diverse machine safeguarding solutions to a wide range of industries in Canada and across North America. If you are looking to make your machines and production processes safer, consult our engineers and get custom machine guards for your safety needs.

The Significance of Risk Assessment in Manufacturing Environments

Mill-Machine

Successful manufacturers search continuously to find sustainable solutions to increase throughput and productivity and minimize production costs. However, at the same time, companies have to enhance their safety standards in order to eliminate the element of health risk. Risk assessment in any manufacturing environment is of paramount significance. A safe working environment increases the productivity of employees.

Risk Assessment

Assessing workplace risks gives business leaders a picture of the existing occupational safety and how they can improve it. Therefore, safety and risk assessment should be carried out to ensure safe installations and operations. Understanding factors that can set a business apart in future is critically significant to risk managers. A full potential of innovative manufacturing solutions can only be materialized when effective risk assessment practices are adopted. Risk assessment process deals with the following questions:

  • What are the project scenarios that might cause damage to workers’ health and environment?
  • Considering the industrial hazards, what number of employees could possibly be affected?
  • What are the potential risks of routine operations or what are the potential accident that can occur during the lifetime of a project?
  • Is there any available data that can help manufacturers judge the likelihood of industrial incidents?
steel-mill

Automation technology and safety

Industrial technology has made incredible contributions towards building safe facilities over the past few years. Workplace safety is one of the prime features of modern industrial automation technology. However, the safety factor cannot be undermined even in a highly advanced industrial environment. Following are some of the hazards associated with robotic work cells:

  • An error in hardware or software system can lead to a dangerous working environment especially when humans have to operate robots.
  • Installation errors can also lead to incidents. Therefore, it is critical to install the robotic cells appropriately.
  • Mechanical failures can lead to a potentially hazardous situation for operators.
  • Lack of knowledge and skills increases the chances of human errors which can ultimately lead to incidents.

The function of safety management is to ensure a safe workplace for employees while the role of engineering is to enhance manufacturing processes. However, both disciplines are interconnected. Traditional machine guarding techniques are simple in design and application, but it is advisable not to rely on obsolete safety methods.

Businesses leaders should understand the importance of risk assessment and preventive measures in order to build a hazard-free working environment for employees. Some automation companies do provide safety and risk assessment services. In Canada, you can consult BP Automation to get a thorough understanding of how you can enhance your machine safety and improve overall productivity by introducing innovative automation solutions to your existing manufacturing processes.

How New Technology Is Revolutionizing Welding Processes

robotic-welding

Forge welding, a process where heated metals were pounded repeatedly until they bond together, was the earliest form of welding that dated back to the Iron Age in Europe. The contemporary welding industry is inspired and equipped with technology that has made welding operations stunningly accurate, fast, and cost-effective. Being a top application of industrial robots, welding has expanded its scope in building sophisticated products for a number of industries. The blog post will explain how modern automation technology is reshaping the welding processes.

Capabilities of welding robots allow assemblers to join parts with great accuracy, pace, and repeatability without wasting resources. It is the emerging technology that has made automated welding devices less expensive and easy to deploy.

Automotive was probably the first industry that deployed robots to make their welding operations more efficient. At that time, it was hard for small companies to use such a sophisticated and expensive technology. However, with the passage of time, robotic welding is now within the reach of small scale manufacturers. Following are some of the examples of how technology has improved the efficiency of welding operations:

Laser welding

Laser welding is one of the modern industrial technologies that convert light energy into heat energy. Laser beam welding is used to join material pieces together through a laser beam. In laser beam welding, radiation emits allowing the beam to travel longer distance without affecting quality. Companies may find it expensive to install laser welding systems in their facilities. However, the reduction in cycle time makes laser welding a cost-effective solution.

laser-welding

Robotic arc welding

Robotic arc welding has improved significantly over the past few years. It requires parts to be positioned in a very rigid and precise position in a fixture particularly designed for that application. Fixtureless welding involves a six-axis robot designed to handle and hold material while welding device performs its part.

Sub-arc welding

Submerged arc welding is relatively old but highly effective tool that deals with heavy duty welding processes. High deposition rate, elimination of time-consuming realignments, and increase in overall productivity are some of the major features of sub-arc welding.

Taking into account the development of new tools and devices, it has become more important than ever to adapt quickly and follow the industry trends. Replacing the outdated production machines with the highly innovative solutions can be a challenging task for medium size and job shop businesses.

Apart from costs related issues, manufacturers have to deal with certain technical aspects. For instance, in-depth knowledge is required to program and operate a robotic welding cell. Small scale manufacturers find it impractical to automate welding for low-volume production runs. However, new technology has made it practical for small and medium size businesses to materialize and understand automated welding and its benefits.

BP Automation is a leading automation solution provider in Canada. We design and manufacture a comprehensive range of modern welding systems tailored to client’s needs. Make a good use of technology so that you can meet the market expectations and stay ahead of the competition.

Trends That Will Continue to Dominate the Manufacturing Industry in 2017

industrial-trends

The global economic expansion is one of the factors that encouraged the manufacturing industry worldwide to adopt new technologies and equipment designed to enhance productivity and overall factory performance. Implementing technological advances continuously helps companies achieve improved output, competitiveness, and customer care. In order to facilitate rapid change and trends, companies need to evaluate the impact, value potential, returns, and risk involved in investing in new technologies.

Given the rising demand for quality and the availability of state-of-the-art capabilities, it is inevitable to prepare for and materialize a more data-driven and connected manufacturing environment where all the activities are connected externally and internally. An easy access to information from operators and customers to factory executives will have a positive impact on productivity. Following are some of the trends that will continue to drive change in 2017:

Industrial robots

Over the last couple of decades, the use of automation technology has grown tremendously. Industrial demand and increased labor costs are the biggest factors driving industries to automate and streamline their production processes. China is one of the biggest consumers of multipurpose industrial robots in the world. According to International Federation of Robotics, the number of industrial robot shipments in China will rise from 75,000 in 2015 to 150,000 in 2018.

3d-printing

The role of robots in creating more efficient manufacturing operations has encouraged manufacturers to replace manual processes with automatic processes; dramatic results produced by factory robotics is an inspiration for industries which are still relying on manual processes. However, some experts are of the opinion that excessive use of automation will result in less innovation as only humans have the abilities to develop ideas that can enhance an existing process.

Industrial internet

The internet revolution is the new industrial revolution. The internet, since its inception, has completely changed the way we communicate, manufacture, buy or sell. The application of internet in the manufacturing facilities has demonstrated great potential in terms of overall production efficiencies. The power of internet to link machines, sensors, and humans can produce and process a great amount of valuable data. The ability of modern devices to process data and convert it into insights help, for instance, operators to monitor production variables and how these variables can influence the productivity.

Additive manufacturing

3D printing or additive manufacturing allows manufacturers to create highly accurate digital designs by building up layers of various materials. 3D printing technology, undoubtedly, is one of the great inventions of the 21st Century. Being a newly developed technology, 3D printing will continue to uncover its potential in prototype development and production processes.

Technological innovations and capabilities make industries think about the possible rewards and risks they can gain from it. However, a slow response to rapidly changing economic conditions can cost industries a fortune. Businesses should follow the prevailing trends and techniques quickly so that they can achieve substantial growth for a long period of time.

Manufacturers should consult the engineering solution providers that simplify technologies and break them down to easy-to-implement solutions. Being a leading automation engineering company in Canada, BP Automation strives to build highly profitable automation solutions including prototype development and automated machines.