Production process development through automation in a metal industry company
Sahradyan, Lilit (2023)
2023
All rights reserved. This publication is copyrighted. You may download, display and print it for Your own personal use. Commercial use is prohibited.
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-202303274186
https://urn.fi/URN:NBN:fi:amk-202303274186
Tiivistelmä
The development of a mid-size deep drawing process through automation was the main aim of this study, which was also aligned with the interests of the target company. This aim was pursued by exploring whether the automation in mid-size deep drawing would bring benefits and what those benefits would be. It also included the investigation of the suitable robot and automation level for this process development. In addition, various methods for investment calculations were required to examine the profitability of the investment. Mixed methods research was conducted, during which the production process development was considered and examined from various perspectives, such as cycle time reduction, robot programming and usage, quality and ergonomics. Both quantitative and qualitative data were gathered from different sources, including measurements, data collection from internal reports, interviews and observations in the target company.
The results illustrated that mid-size deep drawing automation would bring various benefits, such as reduced cycle time due to process standardisation, increased machine utilisation and decreased variability. Another benefit would be the improvement of deep-drawn parts’ quality with an automated process, as a result of standardisation in metal sheet lubrication and precise placement in the deep drawing machine. Meanwhile, the automation of mid-size deep drawing would improve ergonomics and safety as well as increase the morale and productivity of operators. The results also showed that industrial robots would be suitable in mid-size deep drawing with automation level 4. Furthermore, the results revealed that investment in an industrial robot would pay back in a few years and would be profitable for the company. Overall, it was concluded that the target company should consider utilising industrial robots in the mid-size deep drawing for loading and unloading, i.e., with automation level 4. The time-value of money should also be considered when making investment calculations, based on which Net Present (NPV) method for calculations was suggested.
The results illustrated that mid-size deep drawing automation would bring various benefits, such as reduced cycle time due to process standardisation, increased machine utilisation and decreased variability. Another benefit would be the improvement of deep-drawn parts’ quality with an automated process, as a result of standardisation in metal sheet lubrication and precise placement in the deep drawing machine. Meanwhile, the automation of mid-size deep drawing would improve ergonomics and safety as well as increase the morale and productivity of operators. The results also showed that industrial robots would be suitable in mid-size deep drawing with automation level 4. Furthermore, the results revealed that investment in an industrial robot would pay back in a few years and would be profitable for the company. Overall, it was concluded that the target company should consider utilising industrial robots in the mid-size deep drawing for loading and unloading, i.e., with automation level 4. The time-value of money should also be considered when making investment calculations, based on which Net Present (NPV) method for calculations was suggested.