Enhancing Manufacturing Flexibility Through Automation Packaged Solution (APS): A Case Study Approach

Abstract

The use of automation is reshaping tasks in diverse industries, leading to increased productivity and efficiency. The manufacturing sector, in particular, has enjoyed significant advantages from automation, including enhanced quality control, waste reduction, and improved worker safety. However, while the advantages of automation in manufacturing are clear, the implementation of automation in complex manufacturing processes is not without its challenges. One such challenge is ensuring adaptability to new products. In addition, the initial investment for automation in manufacturing processes often presents a significant financial difficulty, particularly in the areas of engineering, design, and programming. The aim of this paper is to provide flexible solutions that can be adopted on any manufacturing line within a short timeframe. This type of flexible solution is referred to as Automation Packaged Solution (APS). APSs involve the deployment of robotic systems and vision technologies to automate specific tasks. The key advantage of these flexible solutions is their ability to adapt to the introduction of new products into the production line without the need for extensive reengineering and reprogramming. The approach involves designing detailed computer simulations based on the initial solutions and bringing the solution to life through an offline commissioning method. In this research, a case study was conducted at a manufacturing plant in Sweden, where two APSs were introduced to their assembly line: Precise screwing and accurate application of product labeling. These APSs play a crucial role in facilitating rapid upgrades and adjustments to automation systems, especially considering the diverse range of product models. This adaptability reduces the time and resources required for reconfiguration and contributes to enhanced operational efficiency, cost-effectiveness, and more sustainable manufacturing solutions. Moreover, it opens up the possibility of transferring these APSs to another production line if the need arises.