As the manufacturing landscape continues to evolve, so does the pressure to automate assembly processes. While automation can drive significant improvements, including cycle time reduction and improved throughput, choosing the right level can feel overwhelming. With numerous options and potential costs, how do you determine what level of automation your operation truly needs?
At Orbitform, our goal is to provide manufacturers with the precise level of automation necessary to streamline their assembly processes—without overcomplicating or overinvesting. With over four decades of experience and providing countless automation solutions for assembly, we’ve identified six key factors that drive decisions around automation:
• Production Volume
• Labor Availability
• Quality Control
• Safety
• Ergonomics
• Budget
Determining Automation by Production Volume
Your annual production volume is a critical factor in determining the level of automation required. Start by calculating your production cycle time using the following variables and equation:
• Annual number of parts required (EAV)
• Number of workdays per year (days/year)
• Available working hours per day (hrs/day)
• Efficiency rate (85% is standard) (eff %)
By using these inputs, you can calculate your optimal cycle time in seconds. In general, the shorter the cycle time, the higher the level of automation required. Conversely, longer cycle times can allow for lower levels of automation, possibly supplemented by operators and simple machines. This balance helps optimize throughput without overburdening resources.
Examples of Automation Based on Production Volume
To better illustrate how production volume influences the level of automation, let’s consider two examples based on assembly volumes.
For a low-volume assembly—such as the production of 100,000 RH & LH Bracket/Stop Pin Sub-Assemblies annually—an operator-driven solution like Orbitform's Standard Orbital Bench Machine would be sufficient. In this scenario, the operator manually loads the pin and bracket and activates the machine. The orbital riveter advances to form the pin and retracts, and then the operator unloads the finished assembly. With an efficiency standard of 85%, this setup achieves a cycle time of 54 seconds per part, balancing labor and equipment for smaller production runs.
In contrast, a high-volume assembly of 500,000 units per year requires a reduction in production cycle time and a higher level of automation. A 4-Station Rotary Dial Machine would streamline the process by allowing simultaneous tasks across multiple stations. Here, the operator loads the parts in the fixture at the first station, and the machine handles the other tasks such as part verification, riveting, and automatic unloading, achieving a faster cycle time of 11 seconds per part. This solution maximizes throughput while reducing the need for manual intervention in the assembly process.
Automation Levels for Labor Shortages
As skilled labor becomes more difficult to source, many manufacturers are turning to automation. By incorporating automation, processes can be streamlined, and the number of required operators can be reduced. This shift not only alleviates labor shortages but also enables manufacturers to add functionality, such as auto load/unload and part transfers, to improve efficiency.
It’s important to consider, however, that higher levels of automation come with increased maintenance and support requirements. At Orbitform, our Equipment Support Team is always available to help maintain and service your automated equipment, ensuring it runs smoothly and efficiently.
Automating for Quality Control Precision
For manufacturers focused on high levels of quality control and traceability, automation offers an ideal solution. Automated systems can monitor quality during production through in-process checks, such as part presence verification and real-time performance data collection. Incorporating automation can also reduce operator handling for complex parts and reduce the chance of operator error during assembly. By utilizing robots, vision systems, and other sensors, manufacturers can reduce errors, ensure quality, and prevent costly field failures.
Choosing Automation to Improve Safety
Automation can also help improve workplace safety by reducing employee exposure to hazardous conditions. With proper machine guarding and automation systems in place, operators can focus on loading or unloading tasks while automated machinery handles the more dangerous work. From servo-driven solutions to robotic integrations, automation enhances employee safety in a wide range of applications.
Automation Solutions for Ergonomic Challenges
Large, heavy, or awkwardly shaped assemblies can create ergonomic challenges for operators. Automating the handling and positioning of these parts can minimize the risk of injury, simplify difficult tasks, and create a safer, more efficient working environment.
Finding the Right Automation for Your Budget
Finally, your project budget will play a key role in determining the level of automation you can implement. The amount of automation you invest in must produce a return on investment (ROI) and stay within your project’s financial limits. At Orbitform, our Sales and Applications teams work closely with you to ensure the best solution for your budget—maximizing both efficiency and ROI.
Orbitform: Your Partner in Automation
By considering these six factors—production volume, labor availability, quality control, safety, ergonomics, and budget—Orbitform helps manufacturers implement the right level of automation for their assembly processes.
For over 40 years, Orbitform has been dedicated to delivering tailored automation systems for manufacturers. From simple pick-and-place units to complex robotic integrations, we offer a wide array of automation options, including:
• Indexing dial machines
• Robotic integration
• Lean manufacturing work cells
• Servo positioning slides
• Part handling and transfer systems
• Fully customized systems
Our process begins with your part. Orbitform’s Applications Engineers review your product, annual production requirements, and your specific reasons for automation. From there, we design a system that fits both your application and budget. Our expert Project Managers guide the process from concept to completion, ensuring that your equipment delivers consistent results. And, once installed, our Equipment Support Team is always ready to keep your machinery running at peak performance.
Not sure which level of automation suits your needs? Contact us today to schedule a free consultation with Orbitform’s experts to discuss your project.
Upcoming Event: Join Us at Our Tech Expo
If you're looking to explore the right level of automation for your assembly process, we invite you to visit us at the Orbitform Tech Expo on October 8th. Our experts will be on hand to discuss your specific application and help you find the best solution to meet your production needs.