The comparison step is still part of the Design phase. It is where you will finally see potential gains. The step is like superposing two transparent slides to compare their differences. Putting the two layouts and processes one over the other will help you find out the potential gains (or losses), how the robot will affect your production process, and what needs to be carried on from the manual to the robotic cell. 

Here’s a list of the topics you should be discussing during your comparison:

Layout

The layout should be done and verified with the team that is most familiar with the manual process. When comparing the "before" and "after" layouts you should seek for:

  • Differences between the cells

  • What needs to be produced or purchased for the robotic cell to work correctly 

  • The impact on the previous or next cell in the process

These need to be addressed during the Design phase so you don’t think about them when installing your robot. The more prepared you are before getting the robot, the faster you’ll go into production. 

Identify Customer

In most cases, the Cobot Palletizing's customer (i.e., the next step of the process) is typically the wrapping station. Generally, this does not change even if you integrate a robot in front of the conveyor. 

Define Output

The output of the palletizing station should be the same, with or without a robot. If there is any difference between the two, make sure to note it and to make changes in the following cell to make sure the process goes on normally. 

Define Input

The input of a palletizing station is usually boxes coming from a conveyor. 

Describe Process

Obviously, the loading will be different from the unloading. The operator will be transferred to another workstation. This means that all the steps that were previously performed by the operator need to be done by the robots. Think about all of them: interlayers, opening the doors, etc. Your cycle time will also change and will be more constant. How will this impact your process?

Document Flow of Information

Information can take all shapes and sizes. In fact, in this specific situation, the robot will need to exchange information with the surrounding machine. Both will need to exchange I/O signals and start/stop instructions in order to emulate the operator. Make sure to manage this situation. Quality control is also important information in the process. 

Measure KPIs

Depending on what your critical KPIs are, you will want to adjust them according to your new production process. If your main KPI is capacity, for example, and if the cobot cell increased the capacity, you have to be ready to live with that fluctuation. Let’s say your palletizing station schedule was set with an operator in front of the conveyor; you might need to adjust the production schedule based on the robot's production rate.

Comparing will allow you to find what you have successfully carried out and what you have missed. It is important to have this discussion with your team before going forward. Having the operator, the engineering staff, and all the people involved is critical for a better integration. 

 

 

Last modified: Monday, 22 March 2021, 2:43 PM