High torque rundowns are usually classified as anything over 100Nm and involve applying substantial force to fasten components securely. 

Manual high torque fastenings can be prone to inconsistencies and errors, leading to potential failures and costly recalls. Torque Reaction is also a problem and can cause injuries and long term illness to operators who are repeatedly carrying out high torque rundowns. 

Automation addresses these issues by providing precise, repeatable, and controlled torque application and with no manual intervention there is no risk of illness or injury to operators.

1. Consistent Quality Control

One of the primary advantages of automation is its ability to maintain consistent quality. Automated systems are programmed to perform tasks with high accuracy, reducing the variability that often comes with human intervention. This consistency ensures that each product meets the exact specifications, leading to fewer defects and higher overall quality.

2. Enhanced Measurement and Inspection

Automated measurement and inspection systems use advanced sensors and imaging technologies to monitor the manufacturing process in real-time. These systems can detect even the slightest deviations from the desired specifications, allowing for immediate adjustments. This level of precision is difficult to achieve with manual inspection, where human error can lead to inconsistencies.

3. Precision Machining

Automation has revolutionized machining processes such as cutting, drilling, and milling. Manufacturing Automation is capable of executing complex operations with extreme precision. These machines follow programmed instructions to the letter, ensuring that each cut and finish is made to exact specifications. This precision is crucial for industries where tolerances are tight, such as automotive & aerospace manufacturing.

4. Reduced Human Error

Human error is a significant factor in manufacturing defects and inconsistencies. Automation minimizes the potential for human error by taking over repetitive and complex tasks. Robots and automated systems do not suffer from fatigue or distraction, which means they can operate continuously with high accuracy. This reduction in human error translates to higher precision and reliability in the final products.

5. Real-Time Adjustments

Automated systems are equipped with real-time monitoring capabilities that allow for immediate adjustments during the manufacturing process. For instance, if a sensor detects a deviation in the machining process, the system can automatically correct the error without halting production. This ability to make real-time adjustments ensures that precision is maintained throughout the manufacturing cycle.

6. Scalability and Flexibility

Automation provides manufacturers with the flexibility to scale production while maintaining precision. Automated systems can be easily reprogrammed to accommodate different product designs and specifications. This adaptability is particularly valuable in industries where product variations are common, such as automotive manufacturing.

1) Increased Precision and Consistency

One of the most compelling advantages of automating material removal is the heightened precision and consistency it brings to the manufacturing process. Automated systems, such as CNC (Computer Numerical Control) machines and robotic arms, can perform material removal tasks with exceptional accuracy. This precision ensures that each part produced meets exact specifications, reducing the variability that often occurs with manual processes. The result is a higher quality product with fewer defects and less waste.

Consistency is another critical factor. Automated systems can replicate the same task repeatedly without deviation, ensuring uniformity across all produced parts. This level of consistency is challenging to achieve with manual labour, where human error and fatigue can lead to inconsistencies.

2) Improved Throughput

Automation significantly enhances the speed of material removal processes. Unlike human workers, automated systems can operate continuously without breaks, leading to increased production rates and reduced cycle times. This continuous operation is particularly beneficial in high-volume manufacturing environments where meeting tight deadlines is crucial.

By streamlining the material removal process, automation allows manufacturers to produce more parts in less time, thereby improving overall throughput. This efficiency can be a game-changer in competitive markets where speed and productivity are paramount.

3) Cost Savings

Automating material removal can lead to substantial cost savings. Firstly, automation reduces the reliance on manual labor, which can be costly and subject to variability. By minimizing human intervention, manufacturers can lower labor costs and reduce the risk of errors that lead to rework and scrap.

Additionally, automated systems optimize the use of consumables, such as cutting tools and abrasives. These systems can precisely control the amount of material removed, reducing wear and tear on tools and extending their lifespan. This optimization leads to lower maintenance costs and less frequent replacement of consumables.

4) Enhanced Safety

Material removal tasks can be hazardous for human workers. The process often involves exposure to dust, noise, and sharp objects, posing significant health and safety risks. Automation mitigates these risks by reducing the need for human intervention in dangerous tasks.

Automated systems can perform material removal in controlled environments, equipped with safety features such as enclosures and dust extraction systems. This not only protects workers from potential hazards but also creates a safer and more comfortable working environment.

5) Flexibility and Scalability

Modern manufacturing demands flexibility and scalability, and automation delivers on both fronts. Automated systems can be easily reprogrammed to handle different tasks and materials, providing manufacturers with the agility to adapt to changing production needs.

This flexibility is particularly valuable in industries where product designs frequently change, or custom orders are common. Automated systems can quickly switch between different material removal tasks, ensuring that production remains efficient and responsive to market demands.

Scalability is another key advantage. As production volumes increase, automated systems can be scaled up to meet higher demands without compromising on quality or efficiency. This scalability allows manufacturers to grow their operations seamlessly.

6) Sustainability

Sustainability is a growing concern in the manufacturing industry, and automation can play a pivotal role in promoting eco-friendly practices. Automated material removal processes are designed to be highly efficient, minimizing waste and reducing the environmental impact.

Precision in material removal ensures that only the necessary amount of material is used, reducing excess and conserving resources. Additionally, automated systems can be integrated with energy-efficient technologies, further reducing the carbon footprint of manufacturing operations.

1) Create a fault-free production line

80% of quality defects can be traced back to human error during the manufacturing process. Mistakes are inevitable and can be caused by many factors, like being overworked and stressed, or lacking the proper training to carry out the job correctly.

Implementing a vision system like Operator Guidance can help to create a fault-free production line. AR increases the accuracy of assembly lines by overlaying instructions, issuing prompts, and carrying out quality checks throughout the process. The result is reduced waste, cost savings and increased product quality.

2) Increase your manufacturing productivity

Time is money in manufacturing. Making optimisations in the production line where possible is crucial to reducing lead times, minimising waste and lowering business costs. By incorporating AR technology in the production process, businesses can cut down on inefficiencies and increase productivity.

Augmented reality removes the need for workers to check paper guides and manuals. By projecting digital instructions right there in front of them, they can complete tasks more efficiently. It also helps to prevent missteps that require time-consuming fixes with precise guidance and real-time feedback.

3) Overcome the skills shortage

British manufacturers are facing the biggest skills shortage since 1989. With fewer skilled operators, the industry is experiencing longer lead times, higher costs, employee burnout and higher turnover. AR helps to navigate the skills gap, so anyone can perform a skilled job without needing prior knowledge of the work.

By implementing vision systems into the production process, manufacturers can train employees on best practices faster and get them to learn on the job sooner — without slowing down production or compromising the quality of the end product. 

Reality: Cobots are designed to assist and work alongside human operators, not replace them. They handle repetitive, mundane, or dangerous tasks, allowing workers to focus on more complex and creative aspects of their jobs. This collaboration can lead to higher job satisfaction and new opportunities for skill development. 

Choosing the right cobot for your facility is crucial to delivering a return on investment. You should first consider what areas in your production line will benefit from a cobot and what tasks you would like to automate, such as repetitive, labour-intensive, or hazardous tasks.

We help and advise on the best cobot solution for your objectives. During your consultation, we discuss the size of your workstation, the payload capacity, and how the cobot will integrate with your existing systems to ensure you get the most value. We can also provide forecasts for return on investment and payback timescales.

Cobots are designed to work hand in hand with operators to adopt routine material removal tasks. The cobot’s interchangeable tools means it can perform many different functions, including: