NRTC AUTOMATION BLOG | INDUSTRIAL ROBOTS AND AUTOMATION
Does Your Robot Just Need Maintenance, Or Should You Decommission?
At what point do you stop robot maintenance and plan to sell or decommission?
At what point do you stop robot maintenance and plan to sell or decommission?
Many manufacturing lines have older industrial robot models that continue to undergo maintenance. Some of these robots may be a few years old, while others have been around for decades.
Remember that an old piece of equipment does not automatically mark it ripe for decommissioning. Some of these machines feature stable components designed to handle the job well for a very long time.
The problem starts when you keep incurring downtime as the robot undergoes maintenance.
How can you tell when to simply perform maintenance and when to decommission? Read on to learn more about appropriately using and selling your robots.
Should you perform maintenance or decommission your robot?
Industrial robot maintenance
Whether you have new or used industrial robots, maintenance is part of the important undertaking that you cannot afford to ignore. Used robots may require more frequent maintenance than new ones, but your production throughput should rarely be impacted.
Working with any industrial machinery requires you to have a maintenance schedule. Remember that every robot undergoes three types of maintenance:
· Reactive maintenance – The type of maintenance done after the industrial equipment breaks down. Whereas this approach saves money in the short run, it can be costly in the long run. Not only does it cause efficiency loss, but it also triggers a premature failure
· Preventive maintenance – This approach sets specific time intervals per industry guidelines for scheduled maintenance that avoids untimely breakdown. It typically covers routine tasks like tightening external bolts and checking the robot repeatability.
· Predictive maintenance – As the name suggests, it involves assessing the current status and using that information to perform only the needed maintenance. Doing so is estimated to save maintenance costs by 18 to 25%.
Pointers to decommissioning the robot
Robots have a certain usable life that ranges from five to 20 years based on the care and type of service it delivers. Here are some of the factors that will let you know it is about time to sell or decommission your equipment:
1. Spare parts are no longer available
Evaluate the cost you normally incur on spare parts annually to keep your system running. Additionally, check the difficulty level over time of getting required spare parts. If vendors start taking longer than usual to get replacement parts or turn down orders because the materials are not available in the market, it could be time to let go of your equipment.
2. The robot breaks down more frequently than it used to
Keep a record of all the breakdowns associated with the robot. Consider important details like the timeframe of the breakdown, the extent of the impact, and the cost of repair. If your report shows that it has been breaking down more frequently in the last few months than it did before, it is likely no longer worth keeping your robot.
3. Quality of products or packaging has gone down
Robots are designed to enforce factory automation, effectively improving the quality of products or services delivered. If you notice that this is declining despite repeated maintenance and components replacement, you would likely have to decommission the industrial equipment. Note that sometimes low-quality service often points to poor maintenance practices. Check existing guidelines to confirm whether something is being done wrongly.
4. Do you still have the skillset to keep the robot operational?
As much as the robot brings automation into your business processes, it will often need someone who knows how to handle it. The older models tend to be complex and require craftspeople to help keep them running. If you have a shortage of those skills, there is a high chance that no one will be able to fix it when it breaks down. In that case, you do not need to wait for failure to happen to start planning on phasing out.
5. Incurs more costs and time on maintenance
Most businesses operate with a certain maintenance budget and an allowed timeframe for maintenance. If you are spending more than usual, you need to seriously consider letting go of the troublemakers. That would help free your resources for more productive work.
NRTC IS YOUR GO-TO PARTNER FOR ROBOT MAINTENANCE AND DECOMMISSIONING
At NRTC, we believe that you should always use highly-efficient equipment to deliver the desired level of automation. When it no longer meets the required threshold, you need to safely let go of it without causing harm to the environment and disrupting your operations.
You can confidently rely on us to decommission your robot when it no longer functions effectively. We have trained personnel with relevant skills and toolsets to get the job done correctly. Visit our site to learn more about our decommissioning services.
How Can Predictive Maintenance Save Your Production Line?
NRTC Automation breaks down predictive maintenance so your production line stays up and running.
NRTC Automation breaks down predictive maintenance so your production line stays up and running.
Improving your manufacturing processes is all about efficiency.
What will take you to the next level of production? How do you increase throughput and capacity while minimizing costs?
One way to do that is through predictive maintenance.
Learn more about predictive maintenance and why you should implement it into your industrial equipment below.
What is predictive maintenance
Predictive maintenance helps determine the conditions of equipment or vehicles for future maintenance needs. It evaluates the condition of industrial robots and manufacturing equipment by using both periodic and continuous monitoring.
The ultimate goal of predictive maintenance is to schedule repairs ahead of time to prevent costly downtime events. This approach to industrial automation favors cost-effective practices over performing routine maintenance when your asset is already experiencing some sort of issue.
How does predictive maintenance work?
The way predictive maintenance approach works is a lot different than just inspecting your vehicle or your asset once a year and making any adjustments that need to be made. It involves the following technologies to test for any maintenance issues:
Infrared monitoring
Acoustic (discharge & airborne ultrasonic)
Corona detection
Sound level measurements
Vibration analysis
Oil analysis
Industrial machinery is prone to wear and tear. If you manufacture parts or products with industrial automation, no matter your industry, it is always recommended to use predictive maintenance system in your facility management plan.
8 ways predictive maintenance can save your production line
1. Cost savings
Knowing exactly when maintenance is going to occur in the next day, week, months, or years makes it easier to budget for these repairs. Being prepared allows you to avoid major damage before it happens, which turns into serious savings. You can accordingly plan your maintenance shutdowns so they don’t happen during regular operating hours.
2. Greater insight
Properly installed predictive maintenance software will immediately notify you when something is going wrong within your system, giving you greater insight into the problem right as it occurs.
3. Find problems before they happen
For automation businesses, having to shut down for an unexpected time because your system is experiencing some sort of damage or error is not ideal. With predictive maintenance, it can tell if your system is slacking in one place and it’ll notify you of any errors immediately.
4. Reduce downtime for repairs.
Because predictive maintenance is always regulating and monitoring your equipment, it can notify you when you have a faulty piece or component, allowing you to plan for repairs. If your system notifies you that a machine is low on grease, you can schedule in time for the repair and not have to disrupt your normal operating hours.
5. Increase service life
Providing industrial machines with regular maintenance and handling any issues before they arise result in a longer usable life. With proper care and maintenance, you can increase the ROI of your equipment.
6. Increase production
By adding in predictive maintenance software, you can increase production by as much as 30%, allowing you to increase your bottom line. Plus, since your machine will be more readily available due to scheduled maintenance, you won’t ever have to worry about losing unexpected work hours during the day.
7. Better safety
When you are notified of any system failures or potential system failures, your team can react accordingly. This keeps employees safe, reducing the potential for danger in the work environment.
8. Fewer machine failures
Regularly monitored machinery results in fewer failures. Predictive maintenance software is constantly checking the condition of the machinery to ensure that it is working properly and up to standards. If it senses even the slightest inconsistency, it will alert you immediately so you can plan accordingly.
Benefits of predictive maintenance
Predictive maintenance can take guessing out of your maintenance plan, which can greatly benefit production throughput and capacity.
Cost-saving - The biggest reason businesses add this into their system is to save money long term. Predictive maintenance can save you a lot of money at one time by catching problems before they get unfixable.
Less downtime - The more errors caught early on in your system, the better your machines will work and the less time they will have to be shut down for unscheduled maintenance and repair.
Safety & protection - Predictive maintenance can catch potential safety hazards – keeping your employees and your machines safe and protected.
Longer life cycle - Since your machines will be maintained more often than normal, they are guaranteed to last you longer since they will always be in proper working order.
There are some expenses to predictive maintenance that you have to consider before jumping in.
Up-front investment - Adding predictive maintenance software to your business is an investment for the future of your company.
Intellectual labor - Predictive maintenance also needs a skilled employee to gather the data and interpreting it.
Having a well-rounded understanding of predictive maintenance, along with its benefits and expenses, will allow you to plan accordingly when building out your production line.
START AUTOMATING EFFECTIVELY WITH NRTC
NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.
From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services.
Contact us today to learn more about how we can help you meet your production goals.
How to Stay Ahead in Manufacturing in 2021
“The present is theirs; the future, for which I really worked, is mine.” ― Nikola Tesla
“The present is theirs; the future, for which I really worked, is mine.” ― Nikola Tesla
Although the manufacturing industry experienced setbacks due to the COVID-19 pandemic, there is still an opportunity for growth.
2021 will prove to be challenging because it will require manufacturers to think differently about their production processes. New technologies and techniques are needed to stay competitive in the post-pandemic world.
Read below about common errors that cause manufacturers to fall behind, and tips to get (and stay) ahead in 2021.
How to stay ahead in manufacturing in 2021
What causes manufacturers to fall behind?
Falling behind in manufacturing means losing revenue and potential customers to competitors due to avoidable errors.
What are some of these avoidable errors?
Not integrating new technologies: Manufacturers who keep up with technology and industry trends stay afloat in the competitive global market. Manufacturers who do not will miss out.
Being disorganized: Organization is key to productivity and overall company health. A disorganized manufacturing company is likely to have more errors that can potentially cost customer relationships.
Sleeping on data: If manufacturers aren’t using their data as the cornerstone to improving production, they are neglecting the full potential of their production lines.
Not utilizing talent: The people who work on the factory floor, as well as other staff in the company, are crucial to the success of the company. By not continuing their education, manufacturers run the risk of missing out on happier, more skillful, and more productive employees.
Not using lean manufacturing: Lean methodology gives manufacturers the chance to increase revenue while improving customer experience. When lean manufacturing isn’t prioritized, companies experience considerable losses.
What are the risks of falling behind competition?
It’s a jungle out there. If you don’t keep up with competition by making the errors listed above, you run the risk of seeing these effects in your production line and your bottom line:
Missing out on important data
Longer equipment downtime
Lower production efficiency
More wasted product
Less demand
We would venture to say that it’s simpler to stay ahead rather than stick with traditional manufacturing methods.
While implementing these new technologies and techniques may incur growing pains, the changes that are established will make it easier to track energy usage, spending, and productivity in the long run. With these measurements, you can effortlessly adjust production to meet your goals.
5 tips to stay ahead in manufacturing in 2021
To leave unnecessary risks in 2020 and continue growing your business this year, check out these five tips.
1. DIVE INTO IOT
The Internet of Things (IoT) has exploded over the past few years, providing manufacturers with the intercommunication necessary between industrial equipment for highly-refined production.
63 percent of manufacturers believe that using IoT technology will increase profitability because it allows industry professionals to develop strategies using real-time information from their production lines.
Innovation is the heart of manufacturing since the Industrial Revolution. By keeping up with technology, manufacturers can stay relevant and maintain satisfied customers.
2. KNOW MARKUP COSTS
Year after year, costs are driven up by inflation. These markup costs could detonate your manufacturing budget and reduce your bottom line significantly.
Aim to do strategic cost analyses regularly to stay informed about the latest developments in costs. This includes everything from raw materials to labor costs.
Also, consider analyzing your competitors’ prices to stay competitive.
As the saying goes, knowledge is power. Put yourself in a better position to make educated purchasing decisions and stay ahead of rivals with consistent cost analysis.
3. KEEP UP ON MAINTENANCE
Equipment breakdowns can result in massive downtime costs; for example, one minute of downtime can cost an average of $5,600 on the production floor.
Prevent costly unplanned downtime while also extending the life of your equipment by maintaining them on a regular basis. You can do this through a smart predictive maintenance program or simply by keeping a spreadsheet.
Whichever way you do it, as long as you stay on top of equipment repairs and part replacements, you are saving your facility from expensive human errors.
4. IMPROVE PRODUCTION WITH 3D PRINTING
Additive manufacturing isn’t new, but with new developments, it is bursting onto the manufacturing scene in a new way.
3D printing makes prototyping and production faster, easier, and less expensive. You can test products and troubleshoot products without the high costs of traditional manufacturing, supply products on demand, and keep fewer materials on hand which reduces your need for expensive warehouse space.
Adding a 3D printer doesn’t have to break the bank, either. You can purchase or finance a refurbished printer at a fraction of the cost of new equipment. If you’re in the market for additive manufacturing equipment, check out the iGAM Marketplace.
5. GET LEANER AND MEANER
Lean manufacturing is fundamental to manufacturing in 2021. Gone are the days where incurring material and energy waste wouldn’t heavily impact the bottom line.
Now, to stay competitive, you need to be aware of how much time, money, and resources you are using to produce your goods. Even minor setbacks can cause you to lag behind global competition.
Check out this article we wrote on Robotics and Automation News to learn more about sustainable and lean manufacturing methods, such as kaizen, 5S, and kanban. Plus, you can learn more about lean terminology and other industrial automation terms on our glossary page.
Act now and reap the benefits
A future of growth and prosperity is within reach, despite the struggles of 2020. With these five tips, you can get ahead of the competition.
SCHEDULE A FREE CONSULTATION WITH NRTC AUTOMATION
NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.
From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services.
Visit our website to schedule a free consultation today.