Automated machine tools. Enhanced productivity, better quality

Transcription

1

2 Automated machine tools

3 The advantage of human workers Flexibility Sensitivity Creativity KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page3

4 Manual loaded machine tools One worker per machine? Worker has to wait for the machine One worker on many machines? machine has to wait for the worker KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page4

5 One worker, many tasks KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page5

6 The advantage of automation Consistency Reliability Availability KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page6

7 Robot loaded machine tools One robot on one machine KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page7

8 Robot loaded machine tools One robot for several machines KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page8

9 Why should I automate 100% utilization of your machine tool potential: maximize your machine productivity by automation. Manufacture even complex parts with higher quality and reliability while reducing costs at the same time. manuell Yield loss automatic Revenue increase 1,00% 0,50% 10,73% 0,50% 0,25% 4,84% 0,10% 0,05% 0,90% Improved Reliability and Quality waste treatment 8% tools 9% shut down 10% others 3% planning 6% maintenance 15% Invest 14% manpower 35% Reduced Labor costs Part output over 8hour shift parts per 8 hour shift theoretical output at 100% Output on 8 hour shift with 90sec per part robot output at robot output at 98% manual output best m % case Higher Throughput Shorter Delivery time parts per 15min inverval Manual loading Robot loading Uninterrupted Manufacturing Increased Value of the Workplace No risk Of turnover Reduced complexity KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page9

10 Improved reliability / quality Attention span of a human being ~ 20min Attention span of a robot = hours Loss of attention mistakes lost money Wrong processed parts caused by: - Part placed incorrectly - Part poorly clamped - Part chipped during load, unload or storing - Manufacturing step missed Will not happen with robot handling. Calculation example: Jobshop with raw part costs 5 Dollar, margin 0.3 Dollar 1 miss-processed part eats the margin of 16 good parts manuell Yield loss automatic Revenue increase 1,00% 0,50% 10,73% 0,50% 0,25% 4,84% 0,10% 0,05% 0,90% KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page10

11 Reduced labor costs respectively additional shifts Labor 35% of life cycle costs Labor costs in the Shanghai area rose by 30% in 2013 One worker can run multiple automated machines without the risk of machine waiting time Machine can run overnight without worker present waste treatment 8% tools 9% shut down 10% planning 6% maintenance 15% others 3% Invest 14% manpower 35% Average lifecycle costs over 10 years. Source: Daimler KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page11

12 Higher throughput Worker productivity 63% to 84% (study by GEO/Fabrik des Jahres 2010 in Germany) Robot productive 98% to % (Source: leading German car manufacturer) Example: Machining time 90sec per piece 3 x 3min per day for toilet 6 parts less produced lunch break 20 parts less produced how was your weekend? from a coworker 5 parts less produced Productivity: worker 74% versus 98% of the robot at 90sec machining time automated cell makes 77 parts more per 8 hour shift. Output on 8 hour shift with 90sec per part 350 parts per 8 hour shift theoretical output at 100% robot output at % robot output at 98% manual output best case manual output worst case KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page12

13 Shorter delivery time Regular work 1 shift / day. Big order need to work 3 shifts, but not enough worker lost order / customer Robot work overnight without complain fulfilled order / happy customer Example: new order comes in on Tuesday morning, it takes 5 hours to program the part, 40 hours to manufacture all ordered parts, all parts will be ready for shipment on Tuesday night the following (!) week in a one shift production (no weekend work). on Thursday night in a two shift production (to late for shipment the same day) on Thursday early morning in a automated three shift production (even with 3 additional hours to get the automation ready) 5 days earlier than one shift production 1 full day earlier than two shift production or 2 days after order entry instead of 3 days KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page13

14 Uninterrupted manufacturing As discussed on previous pages the robot needs no break s and he has a MTBF (mean time between failure) of hours (Source: leading German car manufacturer) with an average of 10 hours preventive maintenance per year. Otherwise the robot is continuously working and producing parts with a reliable part-topart time. This generates a continuous stream of parts and therefore reduces the need for buffer stations between manufacturing steps. Part output over 8hour shift parts per 15min inverval Manual loading Robot loading KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page14

15 Increased value of the workplace and replace unattractive workplaces Short cycle time = Stressful Long cycle time = boring Shop floors are Hot Dirty Loud Programming robots is Clean Interesting Considered high level work KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page15

16 No risk of turnover Turnover of workforce generates high costs. With robot automation Work becomes more attractive, leading to less desire of people to leave the company Robots will not leave for a better paid job next door. KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page16

17 Reduced Complexity Managing productions with hundreds of workers requires a lot of management. Planning for Sick Days Vacation Turn over Training Managing a high volume of different parts (customizing) requires a high organization level and oversight in manual handling factories Robots are trained and setup once for every work piece. Program can be recalled by using bar codes or program numbers. Intelligent gripper can detect / verify the part specification. KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page17

18 Customer specific cell example: KUKA hall 10 KR Quantec on DMG machine Processing of 2 different casting parts for KUKA Robot hand axis Manual loading: 2 shifts 48min process time on the machine 600 parts per month Robot loading: Third shift manless 40min process time + additional tasks by KUKA robot 1080 parts per month 80% increase of machine output production hours per year KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page18

19 Easy use HMI: A graphical user interface allows even un-experienced workers to control the application KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page19

20 The past KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page20

21 The future KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page21

22 Outlook Pressure on the part costs will increase further Lot size will decrease because of customizing Part complexity is increasing Labor costs rise globally Especially in China work force is limited, and employee loyalty is decreasing Especially in China people are looking for office jobs, not workfloor jobs KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page22

23 How can we summarize? Machine tool automation makes your machine tool more productive Automation saves jobs Technology is available and well proven Automate today and be ready for tomorrows challenges Automation from lot size 1 to or more Ease of use without specific robot knowledge using KUKA software packages KUKA Roboter GmbH MSM Schuhbauer 21.April 2015 Page23