NRTC AUTOMATION BLOG | INDUSTRIAL ROBOTS AND AUTOMATION

Lydia Sanderson 2021-11-17 Lydia Sanderson 2021-11-17

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.

Jaydip Patel 2021-11-08 Jaydip Patel 2021-11-08

What is Digital Manufacturing?

Digital manufacturing is the future of production and automation.

Digital manufacturing is the future of production and automation.

Manufacturing has traditionally been a numbers game: giant assembly lines mass producing products in vast quantities. Mass production is no longer the predominant model.

Manufacturing is trending towards a different future—one in which products can be produced on a dime and respond to changes in customer demand. Consumers are demanding higher-quality, customizable products, and on-demand products.

The result of demands placed on manufacturing is two-fold:

Lifecycle Churn: Consumers replace their products more often. In fact, one-third of home appliances and 60 percent of TVs are replaced with a better product, even when they continue to function. If companies want to keep up with consumer demand, they’ll need to constantly innovate and launch new SKUs.
Greater Customization: Mass production strategies cannot efficiently produce customized products. For example, a line of drones may be produced for a variety of applications. Each SKU will require different hardware, software, and systems which leads to multiple short production runs for each model.

The digital revolution in manufacturing is essential for satisfying these emerging demands.

What is Digital Manufacturing?

With the emergence and refinement of new and traditional technologies, manufacturing is becoming a multi-disciplinary field. Digital manufacturing, in particular, is becoming more prevalent across industries.

Digital manufacturing is an interdisciplinary approach, combining elements of design for manufacturability (DFM), computer-integrated manufacturing (CIM), flexible manufacturing, and lean manufacturing.

Digital manufacturing is the co-creation of product and manufacturing processes using a computer system. By linking systems and processes across production, the computer system is able to model and iterate on manufacturing designs and processes before creating the final product or assembly line layout.

An automotive original equipment manufacturer (OEM), for example, can model its manufacturing process (including tooling, assembly, and factory layout) while designers iterate on the next car lineup. Product and manufacturing designers can collaborate throughout the product life cycle, catching mistakes and identifying constraints early.

Types of Digital Manufacturing

DIGITAL MANUFACTURING LIFECYCLE

The digital manufacturing lifecycle is composed of three main parts: product, factory, and value chain management. Each aspect of the lifecycle is tied to manufacturing execution.

First, the product lifecycle includes engineering design, sourcing production, and service life. Digital data is utilized and necessary revisions to the design are subsequently made during that stage.
The smart factory leg uses automation and industrial internet of things (IIoT) technologies such as smart machines, sensors, and tooling. IoT provides instant feedback during operation, allowing greater visibility, control, and optimization. Enhanced business intelligence systems perform in-depth analysis, leading to insights into areas of performance or process improvement.
Value chain management aspects refer to optimizing for process and inventory while assuring quality. The result is decreased inventories, optimal process integration, and better customer satisfaction.

Benefits of Digital Manufacturing

Digital manufacturing strategies help companies recognize the benefits of product lifecycle management (PLM) in a number of ways. At its core, the main benefits are related to producing more, faster, and at a lower cost.

The benefits of digital manufacturing include:

Reduction in manufacturing waste: It’s estimated that 68 percent of manufacturers have reduced their bottom line as a result of excess materials, labor, packaging, and shipping. Through design modeling and optimization, predictive analytics, as well as an efficient response to demand. For example, digital data may be shared with contracted manufacturers to order just the right number of items, avoiding waste.
Mass customization: The use of computer-assisted control (CAD) and automation allows customization of product SKUs, without iterating on the production line. The result is the ability to continuously iterate on designs and manufacture products in smaller batches. Additionally, companies can utilize software to manage production, rendering low volume production runs more economical.

Avoidance of costly errors as a result of missed or misinterpreted data
Facilitation of more efficient factory lineups and models, with optimum layout
Enablement of quality data sharing through CAD-based machine inspections for industrial robots and machine tools
Improved visibility: IIoT sensors allow real-time visibility into the process, equipment, and systems. Technicians can optimize machine use and perform preventative maintenance using remote monitoring technology. Additionally, machine data can also be integrated with other data sets to optimize production—including the entire supply chain.
More rapid pace of innovation and enablement of six-sigma and lean initiatives by analyzing dimensions with a graphical environment. For example, digital manufacturing can help automate time consuming processes, such as front-end engineering.

Take Advantage of Digital Manufacturing

Capitalizing on digital manufacturing is essential for companies of the future. Consumers will come to expect higher-quality products delivered on faster time frames for a lower cost.

The best way to get started with digital manufacturing is through small projects that impact safety, efficiency, or quality. Projects may be value-driven based on customer journeys to maximize ROI. Consider collaborating with manufacturing floor technicians who can identify the best projects and increase adoption.

Plan to scale only after completing a series of successful projects. First, deploy to a manufacturing line, and the plant level next. Finally, develop a strategic plan to overcome roadblocks and embed technologies into future plants. It’s also important to continuously develop and invest in new roles and capabilities through upskilling programs.

Ultimately, a successful strategy to scale digital manufacturing is focused on business value. According to Mckinsey, aspirations should be linked to real and specific business needs.

Industry 4.0

The digitization of manufacturing has been nicknamed “Industry 4.0” because it represents the fourth revolution to occur in manufacturing. Industry 4.0 builds on Industry 3.0, which is when computers were first introduced to manufacturing.

According to Mckinsey, pioneers of Industry 4.0 have recorded 30-50 percent reductions in downtime, up to 3 percent improvements in productivity, and 20 percent declines in quality cost. Manufacturers aren’t deploying technologies at the same rate: many organizations are stuck in “purgatory”: they have no strategy to scale across their network.

Failure to implement digital manufacturing technologies will render businesses stagnant in the near future. Digital manufacturing will someday become essential to remain competitive. Businesses that stay ahead of the curve will continue to have an edge.

GET AHEAD WITH NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Lydia Sanderson 2021-11-04 Lydia Sanderson 2021-11-04

5 Types of Industrial Robots

Learning more about industrial robots will help make automation easier for any manufacturer.

Learning more about industrial robots will help make automation easier for any manufacturer.

It’s estimated that nearly 45% of production can be automated with robots.

There’s a variety of industrial robots available to suit nearly every need. In order to choose which type of robot is best, it’s paramount to start from the paradigm of “form follows function”. In other words, the choice of robot form factor should be dependent on its purpose.

Because there’s a wide variety of tasks that can be accomplished with industrial robots, consequently, there’s a number of robot varieties available that are suited to different types of tasks.

Learn more about the advantages of each type of industrial robot below!

What is an industrial robot?

A widely accepted definition for an industrial robot by ISO 8373:2012 is “an automatically controlled, reprogrammable, multipurpose manipulator, programmable in three or more axes, which can either be fixed or mobile for use in industrial automation applications.”

Though industrial robots are available in various form factors depending on the task, the most common industrial robots are automated arms. These robots can be classified into a few different categories based on movement, application, architecture, and brand.

Types of industrial robots

The most common type of industrial robot is a stationary robot--meaning robots that are bolted to a surface such as a floor, ceiling, or walls. There are five main types of stationary robots (or “robotic arms”) available today that can accomplish tasks such as sorting, welding, and finishing. According to the International Federations of Robots, the five main types of industrial robots includes SCARA, Articulated, Cartesian, Delta, and Polar.

ARTICULATED ROBOT

Advantages: Joints allow flexibility of movement. As a result, a broad range of tasks may be performed.

Disadvantages: Articulated robots are more costly compared with other robot arms, and require more sophisticated control systems.

The most common industrial robot structure is the articulated arm, which accounts for 60% of installations worldwide, according to the International Federation of Robots. These robots resemble a human arm and have structures analogous to a shoulder, elbow, and wrist.

Articulated robots have between two to 10 joints which allows them a flexible range of motion to accomplish dynamic tasks. As the number of joints increases, the more “smooth” the robot’s motions become.

Typically, articulated arms can pivot six degrees of freedom. Although this is less than that of the human arm which can rotate seven degrees of freedom, the range of motion is sufficient for almost any task.

The robotic arm may be attached to a gripper, which is analogous to a hand. The gripper may be as simple as suction cups or as complex as hand-like structures with fingers that can grip and pick up objects.

Similar to robot type, the type of gripper is dependent on the task. Alternatively, grippers may be drill bits, sanders, lasers, and almost any type of specialized tool.

Because of their flexible range of motion allowed by joints, articulated robots have many applications. They are used most often for printing, packaging, welding, machine tending, material handling, and metalwork.

SCARA ROBOTS

Advantages: Cost-effective, accurate, and proficient in a variety of assembly approaches.

Disadvantages: Limited range of motion and less efficient than Delta robots

SCARA is an acronym for Selective Compliance Articulated Robot Arm and describes robots with two parallel rotary joints. While SCARA robots are faster than Cartesian robots, they are less precise. Though they are able to move along all three axes, these robots specialize in lateral movements.

SCARA robots revolutionized small electronic manufacturing because of their small footprint, simplicity, and low cost. They are particularly well-suited for assembly applications. The “C” in SCARA stands for “compliance” and refers to the small amount of “give” in its horizontal plane. However, SCARA robots are rigid in their vertical plane, hence the naming structure of “selective compliance”.

SCARA robot’s selective compliance is helpful for inserting parts into single-planes like circuit boards. Fitting a part into a hole requires some rigidity that is not possible with other types of robotic arms. However, SCARA robots have lower weight limits and fewer degrees of freedom due to this design.

CARTESIAN (RECTANGULAR) ROBOTS

Advantages: Can be more cost-effective and have simpler controls, with greater accuracy.

Disadvantages: Can only move linearly in three dimensions.

Cartesian robots operate on three linear axes (forwards and backward, up and down, and side to side). They get their namesake because they operate on the Cartesian Coordinate system (X,Y, and Z). In other words, they move horizontally and vertically in each ninety-degree plane.

Cartesian robots are frequently utilized for material handling, 3D printing, packaging, drilling, and storage or retrieval. Because Cartesian robots only operate linearly in three dimensions, their actions are more accurate. Additionally, they are more cost-effective and have simpler controls.

DELTA ROBOTS

Advantages: Quick and accurate motions.

Disadvantages: Weight and range of motion restrictions.

Delta robots are popular in the manufacturing of food, pharmaceuticals, and electronics. Delta robots are frequently described as “spider-like” because they are crafted from jointed parallelograms connected to a base and are typically mounted above a workspace.

The Delta robot has sweet origins--it was originally created to pick up pieces of chocolate and place them in a box. Because of its light design, its motions are accurate and very fast.

POLAR (SPHERICAL) ROBOTS

Advantages: Simple control systems, long reach, and fast operations.

Disadvantages: Less flexibility compared with articulated arms and require larger footprints.

Polar robots, also known as ‘spherical robots’, possess an arm attached to two rotary joints and one linear joint. These robots move along polar coordinates, which allows a spherical range of motion.

The first industrial robot ever created was a spherical robot named “Unimate”. Unimate worked on General Motors assembly lines beginning in the 1950s, transporting die castings and welding parts onto auto bodies.

While still in circulation, polar robots are considered slightly obsolete technology that can be replaced by more versatile articulated robot arms. However, polar robots can still be more cost-effective.

When deciding on which type of robot to select, it’s most important to decide on the task or set of tasks it’s required to perform. Additionally, prospective robot owners will need to think about interoperability with existing infrastructure. With a range of options on the market, manufacturers can weigh the costs and benefits to decide on the best model for their needs.

AUTOMATE WITH NRTC

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Lydia Sanderson 2021-09-28 Lydia Sanderson 2021-09-28

Global Industrial Robotics: Growing and Emerging Markets

NRTC Automation reports on the current state of automation around the world.

NRTC Automation reports on the current state of automation around the world.

The International Foundation of Robots (IFR) predicts there will be nearly 4 million robots worldwide by 2022. Despite short-term declines in industrial robot adoption as a result of COVID-19, the global average robot density achieved a new record of 113 robots per 10,000 employees.

While the global outlook is promising, automation maturity is very variable from country to country.

Global Industrial Robot Market

INDIA: 4 ROBOTS PER 10,000 EMPLOYEES

Although India severely lags behind global robot density, the country is one of the fastest-growing among emerging Asian markets.

Traditionally, the strongest driver of robot installation is the automotive industry, which accounted for 44% of installations in 2018. However, the general industry, which consists of the rubber and plastics, metal, and electrical / electronics industry, has recently overtaken automotive.

The gap in robotics automation in India is commonly attributed to:

Absence of adequate hardware ecosystems: Robots require high-end components, the majority of which need to be imported into India.
Robot expense: On top of the high cost of industrial robots, import tariffs and taxes are 28.85% in India. In comparison to the low average annual wages for workers, robotics can be prohibitively expensive.
Deficit of expertise: Robotics requires specialized skills and education, which is lacking in the country.
Late to market: India entered the robotics race late, compared to other nations. Therefore, India’s robotics industry is still catching up.

MEXICO: 33 ROBOTS PER 10,000 EMPLOYEES

While Mexico lags behind the global average at 33 industrial robots per 10,000 workers, it displays modest growth. The country is expected to hit nine thousand industrial robotics sales in 2021.

Automation is most prevalent in Mexico’s automotive and auto parts sectors, trailed by semiconductors and electronics.

Mexico is one of the world’s largest economies and includes a variety of manufacturers. Since many U.S. manufacturers have moved their operations to Mexico, the country has even more motivation to further automate.

UK: 85 ROBOTS PER 10,000 EMPLOYEES

The UK lags behind major global and European competitors in its industrial robotics usage. Industrial robots in the UK are most heavily embedded in the food and beverage and automotive industry while demand is trending in manual industries such as construction.

Many experts attribute some of the UK’s stagnation in productivity (measured by GDP per hours worked) since 2008 to its slow industrial robotics adoption. When compared to nations with similar manufacturing output, the UK utilizes fewer industrial robots, and productivity suffers.

Despite lagging in adoption, industrial robotics has experienced a rise in demand. After a short decline following the COVID-19 outbreak, sales of industrial robotics in the UK increased by 52% in Q4 of 2020.

The government recognizes the importance of automation and intends to invest more of its GDP into R&D to catch up to other superpowers.

CANADA: 165 ROBOTS PER 10,000 EMPLOYEES

Canada ranks 18th in the world for robot density and is significantly above the global average in robot density (165).

Robots are primarily used in the automotive industry, where density is high. However, when the automotive sector is removed, Canada’s robot density is merely 71 and lags considerably behind other superpowers such as the U.S. The UK’s robot density is well below the global average, with only 85 robots per 10,000 employees. At that density, you’d only expect to see robots in plants employing more than 140 people.

Canada’s adoption rate is another cause for concern. Average robot density increased by just 20 units (compared to 39 in the U.S.). Although the cost of integration and lack of flexibility are significant barriers to adoption, the country is hopeful that advances in innovation will reduce blockers.

CHINA: 187 ROBOTS PER 10,000 EMPLOYEES

China is still developing robot density and currently ranks 15th in manufacturing robot density worldwide. However, China outpaces the global marketplace in its continued adoption of automation.

Industrial robotics is most prevalent in the Chinese car industry (which has been the largest in the world since 2013). It’s estimated that the industry uses a whopping 500 robots per 10,000 workers. Robotics use is also scaling in electronics and logistics, which average around 50 robots per 10,000 workers.

China’s robotics industry experience rapid growth throughout 2020 and 2021. According to the IFR “It is the fastest-growing market worldwide. There has never been such a dynamic rise in such a short period of time in any other market.” The country now accounts for 45% of all global industrial robot shipments.

While the country boasts a large workforce, the cost of labor continues to increase at a higher rate than other manufacturing countries like Vietnam. Therefore, China is incentivized to automate manufacturing to improve output and quality.

China’s long-term strategy is to support robotics startups in key industries and expand industrial robot use from traditional caged robots to robots that work collaboratively with humans.

JAPAN: 364 ROBOTS PER 10,000 EMPLOYEES

Within the last few years, Japan outpaced Germany in robot density. Despite ranking in third place in robot density, Japan undoubtedly leads the world in robot manufacturing. In fact, Seven of the 10 world’s principal industrial robotics companies are headquartered in Japan.

In Japan, even robots are assembled by robots. According to the IFR, the country’s output represents 47 percent of total global robot production.

Industrial robots are most prevalent in the electrical and electronics industry (34% share of operational stock), the automotive industry (32% share of operational stock), and the metal and machinery industry (13% share of operational stock).

Japan is also known for spearheading innovation in robotics technology. The country drives development and testing in emerging technology, such as machine vision, machine learning, and artificial intelligence.

Due to this reputation, the country is considered ground zero for new robotics applications. Enterprise companies like Mitsubishi, Kawasaki, and Denso along with the government drive the continued development of industrial robotics in the country.

According to the International Trade Administration, Japan’s industrial machinery market is expected to continue to experience a growth phase. By 2065, the government is planning for a 40 percent reduction in its total workforce because of its aging population. Industrial robotics is expected to help alleviate the gap.

Start automating today

Advancements in robotics technology, emerging demand for high-quality and sophisticated products, and increasing remote and dangerous working environments will drive automation. Countries with mature or rapidly growing automation strategies will continue to thrive, while many other may be left behind.

WORK WITH NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Lydia Sanderson 2021-09-08 Lydia Sanderson 2021-09-08

Getting Acquainted With Your New Machine: The Basics of Robotic Training

Industrial robotics training is beneficial for both business owners and your employees.

Industrial robotics training is beneficial for both business owners and your employees.

Employees often value the opportunity for paid professional development. Employers may expect benefits like reduced risk, lower employee churn, and efficiency gains.

Learn more about robotics training and how to get started with NRTC Automation below.

Programming and different robot programming languages

In order to complete tasks, robots are either guided in real time or programmed to work autonomously. Today, the majority of modern industrial robots are programmed.

While robots are typically packaged with user interface software, positional data and procedure will typically need to be programming. There are a few common programming methodologies used today:

Teach pendants: The most common method for programming an industrial robot is a teach pendant. Teach pendants are hand-held control systems with several buttons or a touchscreen. Usually, the teach pendant becomes obsolete after the robot has been programmed to perform tasks. Most industrial robots are sold with teach pendants, allowing customers to deploy them without additional software or programming.

Offline programming: A newer method that can be used to automate is offline programming. Offline programming involves the creation of a virtual simulation of the robot’s desired actions. The simulation can be created offline and deployed to the robot when refined. Because offline programming is a newer method, fewer professionals are familiar with it compared with teach pendants. However, offline programming can improve safety and limit disruptions to production.

Lead-through: Lead-through programming involves physically moving a robot through the desired actions. The technique is popular for repetitive actions along a fixed path, like paint spraying. The robot captures the positions along a path and logs them into memory to use later. Though lead-through programming simplifies programming, it has become less popular in recent years because many industrial robots have become prohibitively large to manipulate.

Because of the proprietary nature of robot software, it’s common for robot hardware manufacturers to provide their own software. For example, ABB uses RAPID, FANUC uses Karel, and KUKA deploys KRL.

While there are over 30 robot programming languages due to a lack of standardization, there are similarities between them. Typically robotic programmers are able to gain a broad understanding of programming, without learning each proprietary language.

NRTC Automation offers basic programming to advance troubleshooting to empower teams with the skills and confidence to deploy your industrial automation solutions.

Diagnostics

Critical changes that occur in an industrial robot’s system parameters can result in loss of productivity as well as unsafe manipulator operation. Therefore, monitoring and prognostics are essential for the optimal use of industrial robots.

Today, diagnostics are performed at a regularly scheduled maintenance interval, unless a critical error requires immediate action. However, the prevalence of affordable sensing technology and advanced analytics presents an emerging opportunity for fault detection.

Automated fault detection for industrial robots is challenging because it requires vast amounts of labeled training data under healthy conditions. Therefore, unsupervised machine learning algorithms, which can detect, predict, and alert on faults with high accuracy are gaining in popularity.

Repairs

Frequently, the service needs of intricate production capital are more complicated than the actual robots. Repairs are often expensive, complicated, and unpredictable. While staff may be able to handle ongoing maintenance, repairs can be complex and sometimes require years of experience to resolve.

Industrial robot repairs may involve replacing or even refurbishing components. Additionally, to avoid major delays, it’s important to have the right parts and tools on hand that may be required to fix common issues.

Common issues that warrant repairs include:

Power supply issues: Robots are powered by electricity and they use it in a number of ways, often amplifying or stepping down as needed. The electrical requirements for an industrial robot can be difficult to maintain.

CPU malfunction: Central processing units are also subject to wear and may require repairs to perform up to production standard.

Control panel errors: A number of variables can impact robotic controls, such as frequency and electromagnetic interference.

Incorrect installation or programming: Since installation can be highly technical and specialized to the facility and requirements, leaving a lot of room for error.

Mechanical failure: While many issues can be a result of programming errors, mechanical failure can cause unexpected faults.

Some industrial robotics owners choose to hire an on-staff technician to make repairs, while others decide to outsource to dedicated third-party repair companies. Many robot manufacturers and brokers also offer repair services.

NRTC Automation can conduct a top-down analysis of requirements and recommend a personalized training program to match your repair needs.

Maintenance

When it comes to industrial robots, it’s rarely possible to set it and forget it. Though robots can automate high-efficiency tasks, they require ongoing maintenance.

Regular maintenance has numerous benefits including:

Decreasing downtime
Avoiding loss of production due to undetected problems
Prolonging the lifespan of expensive industrial robots
Increasing production efficiency

Robot manufacturers list different schedules and cadences for preventative maintenance. Common industrial robot maintenance tasks include:

Tightening external bolts: Bolts and screws may loosen over time and should be tightened as needed.
Greasing joints: Periodically greasing joints with the correct grease blends will ensure smooth operation.
Testing and replacing batteries in controller and robot arm
Cleaning inside and out: Over time, robots can accumulate grease, dust, and other particles which may create safety and electrical issues. Grease, filters, vents, and cooling fans must be cleaned regularly to maintain robot health.
50-cycle verification tests: A 50-cycle verification test will provide data on robot operation. The tests will surface many concerns, such as repeatability issues, that need to be addressed.

Programming, repairs, and ongoing maintenance or complex, production robotic machinery can be daunting. NRTC Automation’s personalized training programs can help you get the most mileage out of their machines and learn from experts in industrial robotics.

VISIT NRTC AUTOMATION TODAY

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Lydia Sanderson 2021-08-24 Lydia Sanderson 2021-08-24

How To Evaluate ROI On Industrial Automation

Learn how to calculate ROI on your industrial equipment.

Learn how to calculate ROI on your industrial equipment.

How do you know if you made the right decision by purchasing industrial automation?

You find the ROI, of course!

Calculating the return on investment is a clear way to show how your equipment is generating revenue for your company.

Learn more about the importance of ROI and how to find it below.

Calculation of ROI for Robotic Automation

Manufacturing is a difficult industry to be in, especially in the global market.

How can robotic automation help you with grow within a reasonable budget? In that same vein, what is the return for the investment that you made in automating your processes?

As a manufacturing manager or other leadership position, you deserve to know the exact ROI on an automation product that you buy.

Simple industrial automation ROI formula

The simple return on investment (ROI) formula is always calculated as a percentage.

ROI = Gains - Investment x 100

Investment

From the above formula, it is clear that the higher the percentage, the greater will be the benefits gained by the manufacturing company.

Determine a suitable time duration to consider when computing this formula. This might be 6 months, 1 year, 5 years, or longer. Longer time intervals allow a clearer picture of your ROI.

Calculating ROI may seem complex at the start, but the following steps will convince you about the quality and benefits that robots can bring to your business.

Total cost of industrial automation

Need a more complete picture of your industrial automation ROI? Find out the total expense that will be required to make your company fully automated. This includes the following expenses.

MAINTENANCE COSTS

An industrial robot requires supervision to sustain a long usable life. According to Robotic Industries Association (RIA), the typical maintenance cost of a robot is about $500 per annum.

OPERATION COSTS

Determine the power consumption of a robot per year, as well as the labor involved in programming and operating the robot.

TRAINING COSTS

To understand new machinery or a robotic model, in-depth training may be required. Sometimes it takes weeks of training to learn how to use a machine.

By taking into account these details, you can estimate manufacturing ROI more precisely.

Savings that you can make through automation

To get even more granular, determine the potential future savings of your robot.

HIGHER PRODUCTIVITY RATE

Robots work more quickly and efficiently than humans. They can take extra shifts around the clock without little to no error margin. Find out what your productivity cost savings are by comparing manual work production with robotic manufacturing.

LABOR SAVINGS

Automation industry specialist and former Engelberger Robotics Award winner Ron Potter describes ROI as long-term strategic planning of industries that want to excel.

According to Potter, an average-sized robot consumes 7.35kW of power. Average energy costs are 10 cents per kW. as per 2013 rates of industrial use, defined by U.S. Department of Energy.

That means the average expense of a medium-sized robot will be 75 cents per hour. Comparing this cost to human labor, manufacturers can save between $15 to $20 an hour on labor.

Online ROI calculator

Want a cash flow calculation but don’t have time for the details?

Check out the online ROI Robot System Value Calculator if you want to quickly determine an estimated ROI of your robot.

NRTC Automation services

Want to generate revenue in your manufacturing facility?

Work with NRTC Automation. We offer personalized turnkey automation solutions to help you meet your production goals.

ROBOTIC WORK CELLS

NRTC will design, build, engineer, and install a custom work cell specific to your application needs. We also offer financing on our work cells so you can automate on a budget.

ROBOTIC TRAINING

Our experts will guide your team in robotics education with hands-on experience. Training is provided both on our site as well as at your desired location. Give your employees the confidence to solve all technical issues, starting from basic programming to complex diagnostics.

ROBOT REFURBISHING

Give your old machinery reconditioning treatment to extend usable life and reduce costly repairs with NRTC’s Industrial Robot Refurbishing Services.

TOOL AND FIXTURE STORAGE

Instead of spending valuable time storing and managing extra tools and equipment, send them to NRTC Automation. Your machinery will be stored in a climate-controlled space, and we’ll send it back as soon as you need it.

Automate your facility

By following our guidelines and trusting in our robotic automation technology, you will be able to lower your production waste and boost your revenue.

NRTC Automation is a trusted partner of top auto manufacturers around the world and is here to automate your company for you. So what keeps you waiting? Contact us now if you want to keep up with the pace of the advanced industrial world.

VISIT NRTC AUTOMATION TODAY

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Lydia Sanderson 2021-07-20 Lydia Sanderson 2021-07-20

6 Cybersecurity Methods for Manufacturers

Protect your data and equipment from cyberattacks by using these six recommended cybersecurity methods.

Protect your data and equipment from cyberattacks by using these six recommended cybersecurity methods.

With the rise of IoT and connected industrial automation, manufacturing has becoming more efficient than ever, improving efficiency and cutting down on waste.

Unfortunately, technological advancements come with a hefty price: cyberattacks threaten to destroy companies by exploiting data and damaging industrial assets. For example, the recent cyberattack on the Colonial Pipeline in Texas shook the manufacturing sector after it shut down the pipeline.

Thankfully, manufacturers can avoid these attacks by implementing cybersecurity practices into their businesses. Learn more about the importance of cybersecurity in manufacturing below.

Get smart with cybersecurity tips

What is cybersecurity and when did it become a concern?

Cybersecurity is the practice of protecting and securing internet-connected systems, programs, data, and networks from malicious cyberattacks.

Malicious individuals or groups, commonly known as attackers, hackers, or cyberthreats, attempt to infiltrate systems through methods such as malware, ransomware attacks, and social engineering.

Malware is software that can harm a computer or network. Ransomware attacks are when hackers lock an individual’s computer and demand payment or information to unlock it. Social engineering uses trickery and human interaction to coax individuals into falling for attacks.

Cybersecurity became a concern in manufacturing in 2010 when Iranian PLCs were hacked by computer “worms” called Stuxnet that made sensitive data vulnerable and caused centrifuges to self-destruct.

After this attack, the manufacturing world convened to raise awareness about cyberthreats and encourage companies to protect their systems.

Why is cybersecurity so important in advanced manufacturing plants?

Manufacturing is the most common targeted industry for cyberattacks.

As manufacturing progresses with more integrated systems and the advancement of IoT technology, manufacturing plants and facilities are becoming even more vulnerable to attacks like Stuxnet.

By establishing secure systems, programs, and networks, manufacturers can continue improving their processes with smart tech without the fear of an attack. Other benefits of practicing cybersecurity and risk management include:

Protection of your employees’ data
Improved recovery time after a breach
Confidence to use data to pursue more efficient manufacturing conditions

How to secure your systems and data against hackers

Set up your business for success by taking the time to secure your internet-connected devices and equipment against hackers.

Take these steps to improve your security and protect your data:

Perform a risk assessment to determine your current level of security.
Hire a cybersecurity professional and integrate them with your IT department. They can develop firewalls and other security frameworks to defend your systems.
Educate employees on how to avoid cybersecurity attacks, such as phishing.
Become knowledgeable in cybersecurity literature and standards, such as those by the National Institute of Standards and Technology (NIST).
Consistently monitor and evaluate potential security threats.
Be prepared for a breach. Practicing exercises such as simulations will prepare your teams for a breach and ensure that every team member acts accordingly.

Staying on top of security is a constant yet necessary task. By adding these routines and practices into your manufacturing business, you can protect precious data and assets from exploitation while continuing to grow your business.

Want to start on the path to a smarter factory?

NRTC Automation’s sister company, iGAM, offers a vast inventory with affordable and quality industrial equipment to automate their production lines.

If you want to view data from your production lines, check out our supply:

Make informed decisions to your production line with real-time data with the right equipment.

Plus, iGAM offers two methods to finance your purchase:

If you want to finance with top lenders in the nation, click the “Finance” button on the product page and fill out our short application.
Open a line of credit through Behalf. Create an account with Behalf and get the equipment you need with iGAM.

CONTACT NRTC FOR GUIDANCE WITH INDUSTRIAL AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Schedule a free consultation with us to get started on your automation journey for enhanced productivity and capacity.

Lydia Sanderson 2021-07-07 Lydia Sanderson 2021-07-07

3 Sneaky Manufacturing Costs to be Aware Of

"Before anything else, preparation is the key to success." — Alexander Graham Bell

"Before anything else, preparation is the key to success." — Alexander Graham Bell

Money is the energy that allows companies to grow from small businesses to large organizations that have influence in their industries. That’s why manufacturers should do everything they can to manage costs effectively.

With a bit of preparation, manufacturers can achieve their production goals and increase their customer base.

Learn more about the three sneaky costs in manufacturing below to prepare for growth.

3 costs in manufacturing

Preparation is key

If you want to grow your company, you need to lay the foundations for success.

Part of that foundation is knowing what you are up against and being prepared to meet challenges as they arise, such as expenses.

For small- to mid-sized manufacturers, this is a necessary skill to have to manage costs during the first stages of growth.

Stay competitive with leaders in your industry by charting these costs ahead of time.

3 costs to be aware of in manufacturing

1. Rent

Rent is a major expense.

Warehouse square footage isn’t cheap; in fact, the average rent paid per square foot in 2019 was $6.36, which for a facility on the small side comes out to over $30,000 per quarter!

That’s a whopping $120,000 a year just to shelter your production process.

With that knowledge, do you really want to waste the precious square footage you have?

Plan out your floorplan to optimize your warehouse space. Of course, you should always maintain OSHA standards by allowing enough room between equipment and walking space.

However, there are other methods to fit more production capacity on your warehouse floor. For example, you can store materials and equipment that aren’t being used elsewhere, such as with NRTC’s Industrial Tool and Fixture Storage solution.

Additionally, consider adding a second level to your warehouse if you have the space. Using access structures such as steel platforms and stairs allow you to optimize the vertical space in your facility, giving you the biggest bang for your rent.

2. Maintenance and repairs

According to a Delaware study, maintenance is the largest controllable expenditure in a manufacturing facility and exceeds the annual net profit in many plants. It’s estimated that maintenance costs are between 15 to 40 percent of total production costs.

On top of that, if you don’t perform maintenance correctly, then repairs (or “reactive maintenance”) are even more expensive. Eventually, equipment that isn’t maintained may need to be replaced entirely, which can sink a company that isn’t expecting that large expense.

Some ways to reduce maintenance (and repair) costs is to simplify procedures, create a maintenance schedule for predictive maintenance, and follow protocols to prevent unnecessary injuries to employees or damage to equipment.

For example, according to the U.S. Department of Energy, predictive maintenance saves up to 40 percent over reactive maintenance, making it the clear choice to save costs on equipment.

3. Downtime

Downtime, especially unplanned downtime, can be a killer.

Why? Because the average cost of a downtime incident is $17,000. Considering how 70% of manufacturers don’t maintain their equipment properly and suffer downtime as a result, that means money is burning when it could be used productively.

Downtime is inefficient: when equipment isn’t working, lead time is increased. That creates angry customers who expected to receive their products on time. The worst-case scenario of downtime is losing customers and ultimately losing revenue.

So, how do you battle unplanned downtime?

As mentioned, maintain your equipment using predictive maintenance for the best results.
Train your employees so they have a keen eye for equipment malfunctions and are better prepared to get your production line back up and running.
Finally, use production data to optimize manufacturing processes for high efficiency.

Choose to be a winner

NRTC Automation encourages manufacturers to be prepared in every area of the production process to see success in their business.

Managing costs through preparation will allow manufacturers to make better use of their warehouse space, actively engage in predictive maintenance, and see a reduction in downtime.

Use the tips listed above to enhance your facility. If you need help knowing where to go next, contact NRTC Automation to get expert advice and guidance to reach the next level.

Stay on track with NRTC Automation

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Schedule a free consultation by clicking the button below to start exceeding your production goals.

Lydia Sanderson 2021-06-29 Lydia Sanderson 2021-06-29

How Do Manufacturers Recycle Waste Materials?

Waste in manufacturing is an unfortunate reality. However, manufacturers can actively mitigate the effects of waste by recycling.

Waste in manufacturing is an unfortunate reality. However, manufacturers can actively mitigate the effects of waste by recycling.

Even the leanest manufacturing facilities create waste. Companies, families, and individuals all play a role in the buildup of waste.

However, that doesn’t mean we should give up and let the waste go to the landfill.

Recycling industrial waste is an opportunity to redeem useful metals, glass, and other materials from the scrap produced during manufacturing.

Learn more about how to recycle industrial waste and how NRTC Automation can help below.

Recycling in manufacturing

Source of industrial waste

Industrial waste is produced by manufacturing companies, construction sites, and production and power plants. The waste can be a by-product of manufacturing, like raw materials such as metals, or it may be broken and defective equipment that cannot be repaired.

When a company finishes a project and completes a tear out of their facility, there is a huge opportunity for recycling materials. Recyclable industrial waste is also produced on a day-to-day basis as production occurs and scrap material is left over.

What is tear out waste?

Tear out waste is any material that is not part of the company’s valuable equipment or resources.

Waste can be anything from scraps of manufacturing material to profitable materials like copper, or even remnants from lunch break. It’s important to identify waste production to prevent future debris and to save money and materials. Perhaps it is even more important to identify how to correctly manage waste so that resources are used and energy is saved.

Defining the end-state

One of the most important parts of decommissioning a project is defining the end-state. The end-state is the goal of the project: a broom-ready facility prepared to take on a new project. Defining the actions that need to happen to get to the end-state will outline our strategy for completing a tear out.

The end-state is also necessary for considering how we deal with tear out waste. In order to achieve a broom-ready facility, we will need to manage waste in a way that is both efficient and environmentally responsible.

Common recycled industrial materials

A few of the common industrial materials that are recyclable include:

Scrap metals (copper, iron, aluminum, etc.)
Glass

Plastics
Scrap tires
Chemicals
Digital waste

Most manufacturing by-product can be recycled, which makes it even more important for manufacturers to take action and recycle their waste.

Chemical waste in particular is necessary to recycle, or at least dispose of responsibly, because of the risk of contaminating groundwater and other resources.

Recycling process

Recycling is a standardized step-by-step process from picking up the waste to presenting repurposed materials to be used for new products.

Once the materials have arrived at the processing center, they are dumped and sorted. The sorting process may be done by hand or with automated lines.
The waste will then be processed once it has been accumulated into groups. Waste can be broken down, melted, or separated by parts and reused.
Finally, the waste is transformed into a useable product and can be sold to companies that utilize recycled materials to create new products and be reintroduced to the market.

Repurposed products

Recycled materials can be reused to create repurposed products, such as:

building materials
industrial equipment and storage
glass products
cables

Using repurposed products are cost-effective and marketable for being sustainable.

Let your customers know your green habits! They may be more loyal customers if they know you are doing your part to improve the sustainability of your company.

Prevent waste by recycling usable materials.

You can contribute to the movement toward a sustainable world by recycling viable industrial waste.

Conforming to the Superfund law and keeping waste out of landfills will allow materials to be repurposed, preventing more pollution and litter from soiling the planet.

DO YOU NEED PROFESSIONAL SERVICES TO DECOMMISSION YOUR FACTORY?

NRTC Automation is renowned for our decommissioning and tear out services. We provide tear outs for all industries in factories and manufacturing facilities around the world. With our dedication to complete the project on your time requirements, our strategic planning process, and our team’s commitment to your project, it’s no wonder that we are trusted by the world’s top automobile manufacturers.

Contact NRTC Automation today to discuss how we will decommission your factory according to your standards.

Lydia Sanderson 2021-06-15 Lydia Sanderson 2021-06-15

How Industrial Equipment Can Help You Make Safety a Priority

Thousands of work-related injuries and deaths can be prevented each year with industrial equipment.

Thousands of work-related injuries and deaths can be prevented each year with industrial equipment.

Manufacturing can be a dangerous industry to work in.

Machinery is constantly in motion and chemicals of all kinds are used to manufacture products and materials.

OSHA created standards to protect workers from these potential hazards, and with industrial equipment, manufacturers can align their facilities with these standards.

Learn more about OSHA’s standards for manufacturing and how industrial equipment can help you meet your safety goals below.

Safety in industrial environments

What safety standards are set in place?

OSHA, or the Occupational Safety and Health Administration, is a governmental body dedicated to workplace safety standards in the United States.

Prioritizing safety is important for all industries, but it is especially necessary in construction and manufacturing due to the dangers present in the workplace. NRTC Automation upholds safety as the number one priority in all our services.

Listed below are the top safety standards that all manufacturing facilities are expected to use:

Lockout tagout (LOTO): LOTO are procedures used to prevent equipment from running during repairs and maintenance as well as to prevent spills and leakage of hazardous materials. A lockout device will keep unaware individuals from attempting to use to machinery or materials. A tag will include information about who created the tag and the time of placement. A thorough inspection must be performed if the tag is to be removed.
Permit-required confined spaces (permit space): Workplaces with spaces that are too small for people but large enough for workers to perform tasks is considered a confined space. These spaces require permits from OSHA for workers to access. Examples of confined spaces are pipelines, tunnels, and tanks. They may have some of the following characteristics: exposed live wires, heat stress, converging walls or sloping floors, and more.
Personal protection equipment (PPE): PPE is gear worn by workers to protect them from injury and death. There are different PPE designed for specific hazards, including heat, impact, optical radiation, chemicals, and dust. Common PPE worn by manufacturing workers include safety goggles, face shields, and hardhats.
Machine guards: Using machine guards is especially important in manufacturing where machines are constantly working around human workspaces. There are over 800 deaths per year that could have been prevented with a machine guard. There are several parts that needed to be guarded on a machine, such as the point of operation and around any blades. Each piece of equipment is unique in what machine guards it requires.
Warning signs: OSHA requires certain warning signs to be used in areas where there are hazards such as dangerous chemicals or heavy machinery. They must be able to be universally understood, like using a bright yellow color for caution signs and red for danger signs. Manufacturing facilities must also contain signs for first aid stations and emergency eye wash stations.
Employee compliance: Last but certainly not least, employee compliance is an important part of maintaining a safe facility. Employees must first be aware of the safety standards required by OSHA and the employer must provide the necessary PPE and other tools to keep employees safe. Then, employees must conform to safety standards to protect themselves and others from harm. OSHA inspectors can inspect a facility without warning to ensure safety standards are being met.

With these safety standards set in place, manufacturing workers can perform their jobs without fear of injury or worse, creating a productive and efficient facility.

How industrial equipment can help you make safety a priority

Industrial equipment can do more than increase throughput and capacity in your facility. It can also help you prioritize safety for your workers.

1. INDUSTRIAL EQUIPMENT CAN MAKE WORKSPACES MORE ERGONOMIC.

According to OSHA, workspaces lacking ergonomics are a significant cause of musculoskeletal disorders (MSD) and injuries; in fact, they are the most frequently cited cause of lost productivity.

Using industrial equipment to enhance the ergonomics of your employees’ workspaces is key to preventing potentially long-term injuries. For example, a turntable provides easy access to materials or equipment while helping workers waste less energy and time on extra movement.

Check out iGAM's Fibromat Heavy Load Positioning Turntable for a great deal on safety equipment for your employees.

2. INDUSTRIAL ROBOTS CAN HANDLE THE REPETITIVE TASKS.

Industrial robots are designed specifically for repetitive tasks like material handling, welding, and more.

Repetitive tasks are another source of MSD and injuries. For example, material handling can cause shoulder problems that affect workers for a lifetime.

Additionally, repetitive tasks can be dull and cause workers to drop their attention, which can not only cause problems for product quality and productivity, but it can also pose serious risk to the workers’ health.

By adding an industrial robot to your facility, you can increase productivity while protecting your workers from unnecessary harm.

3. INDUSTRIAL ROBOTS CAN ALSO HANDLE THE HEAVY LIFTING.

Industrial robots, such as this R-2000IC-210F FANUC robot, have a payload capacity of several hundred pounds. Some robots can even lift several tons!

With an industrial robot, you can ensure that heavy materials, parts, products, or equipment are expertly handled without fear of harming your employees.

4. ACCESS EQUIPMENT PREVENT FALLS.

Finally, industrial access equipment such as stairs, lifts, platforms, and ladders assist manufacturing workers with getting to hard-to-reach places without putting themselves in danger.

Falls are the leading cause of death in construction. Along with the right safety gear, access equipment can prevent tragedy in the workplace.

Visit iGAM to shop for stairs, ladders, and platforms for your employees.

Get on top of safety in your facility

Creating and maintaining a safe work environment requires consistent effort and vigilance. However, it’s well worth it when your employees are satisfied knowing their safety is secured.

Work with NRTC Automation and iGAM to protect your employees, no matter what size, phase, or industry you’re in.

SCHEDULE A FREE CONSULTATION WITH NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Visit NRTC Automation today for full-service solutions to improve productivity in your facility.

Lydia Sanderson 2021-06-03 Lydia Sanderson 2021-06-03

Can Robots and Humans Work Together in the Real World?

Automation is a hot-button issue. Get the facts with NRTC Automation and see how robots and humans can work together for a brighter future.

Automation is a hot-button issue. Get the facts with NRTC Automation and see how robots and humans can work together for a brighter future.

Industrial robots are demonized as all-knowing machines determined to destroy families.

While the news may not help this image, reading studies and learning about how industrial robots actually help humans in the workplace will dispel the myth.

Get an inside look at how industrial robots make human lives better below.

Working alongside industrial robots

Addressing the fear of robots taking jobs

The media, as with any controversial topic, does a fine job at creating panic over automation.

According to sources like CNN, millions of low-skill jobs are at the mercy of industrial robots in the next few decades.

Furthermore, fears of humanoid robots taking over uniquely human jobs, such as therapy, is spurred on by threats of science fiction-level artificial intelligence.

However, this is simply not the case.

“Most jobs are more complex than [many people] realize,” said Google’s chief economist, Hal Varian, during a forum on the future of work.

For example, even a simple welding job takes a considerable amount of programming and engineering for a robot to accomplish.

And it takes people to program, engineer, and fix those robots. With robotic training, workers can shift from monotonous and potentially dangerous labor to safer and more creative work.

Plus, consider the fact that there will be over 2 million unfulfilled jobs in manufacturing due to a skills gap by 2030. Unemployment is rampant, but finding workers to fill these roles is getting harder. Industrial automation can close the gap for some positions, but many others require skilled human labor.

Why humans should work with robots

One way to get around this disaster mindset is to think about working with robots, rather than fighting against them for our jobs.

Robots make life better. They can handle heavy weights, withstand extreme temperatures, and work day and night without taking a sick day. These characteristics means our fast-growing population will receive the products and services needed to maintain our quality of life.

Working with robots is becoming easier as well. With collaborative robots, or cobots, workers can perform tasks right next to a cobot without fear of injury. They are designed specifically to make a human’s job easier to perform.

CUSTOMIZE YOUR ROBOTIC WORK CELL

Benefits of using industrial automation

Robots have a lot to offer us humans. By seeing clearly through our fear, we can appreciate how industrial automation improves our lives for the better.

1. ROBOTS PROVIDE A SOLUTION FOR UNSANITARY AND DANGEROUS JOBS.

Labor during the Industrial Revolution, which transformed our world into what we know today, was dirty, difficult, and dangerous.

Factory air was polluted with smoke and soot, regulations for labor were nonexistent, and workplace safety wasn’t considered important, leading to life-endangering accidents. Government regulations fixed many of the problems caused by the Industrial Revolution.

The development of robots in the workplace further enhanced working conditions for people by taking over heavy labor and dangerous jobs that put humans at risk. Jobs like waste management and bridge inspections are being performed by robots, protecting humans from disease, injury, and death.

Today, robots continue to make work environments safer for humans.

2. ROBOTS CREATE JOBS, RATHER THAN TAKE THEM AWAY.

As mentioned above, total automation isn’t possible. Dull, repetitive tasks such as packaging food can be automated, but more complex tasks require far more programming than most robots are capable of (or most companies can afford).

Stanford Business gives the example of a gardener’s daily tasks: mowing is easy to automate, but other chores like weeding, pruning, and watering would be too complex for one robot to manage.

Because robots have provided humans with more leisure and expendable income, industries like video games, dating applications, and gyms are thriving. This creates jobs for designers, writers, personal trainers, management, customer support, and more. These jobs cannot be automated due to the nature of the work, and they are possible because of the relief robots provide from grueling, time-consuming labor.

3. ROBOTS ENHANCE WORKPLACE PRODUCTIVITY AND BRING CONSISTENT, RELIABLE RESULTS.

By taking over the repetitive and boring work, robots allow humans to focus on the important tasks. Not only that, but robots are highly consistent and perform their jobs reliably. This allows humans to know that the job is done correctly and saves time checking for quality assurance.

Automate your facility

As you can see, industrial automation is the future of manufacturing. Robots improve the health and safety of humans while increasing productivity and minimizing downtime on the manufacturing line.

If you are a manufacturer looking to automate your facility, you’ve come to the right place. NRTC Automation can design, build, and engineer a custom work cell for your specific needs. Whether you need a single, double, or triple robot cell, we have you covered.

Alongside our sister company, iGAM, we source and refurbish used industrial robots and manufacturing equipment to create affordable turnkey automation solutions for manufacturers of any size and phase.

Plus, we offer financing so you can automate on a budget. Visit our Financing page to learn more about how you can grow your company with low monthly payments.

Check out our Automation Services video below!

VISIT NRTC AUTOMATION TODAY

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Schedule a free consultation with NRTC today to learn more about how we can help you meet your production goals.

Lydia Sanderson 2021-05-25 Lydia Sanderson 2021-05-25

Unimate: The OG Industrial Robot

The first industrial robot opened the doors to a world of automation.

The first industrial robot opened the doors to a world of automation.

Our world has completely changed in less than a century.

Technology has made life easier in many ways. From cars to phones to elevators, daily life looks very different compared to the early 20th century.

Industrial automation is no different. Because of the Unimate, technology has made its way into manufacturing.

Learn more about the Unimate and how you can automate your facility with modern-day robots below!

Unimate, the first industrial robot in history

What is the Unimate?

The Unimate is the first industrial robot ever created in history. Its inventor, Geroge Devol, patented the Unimate in a small Connecticut town in 1961. Similar to the industrial robots of today, it had a single arm designed for repetitive tasks. The arm weighed an impressive 4,000 pounds.

The automation industry was the first to adopt the Unimate for metalworking and welding.

History of the George Devol and the Unimate

Devol drastically changed the way manufacturing processed and produced with his invention.

Devol was born in Louisville, Kentucky on February 20, 1912. He was 9 years old when the word “robot” first appeared, and, supported by a wealthy background and an interest in electricity and machines, he started building the knowledge needed to invent the Unimate.

Rather than going to college, Devol decided to start his own company. His first invention was the automatic door, or the “Phantom Doorman.”

Several years later, after World War II, Devol and his Unimation Corp. company developed a machine called the Programmed Article Transfer, which slowly evolved into a robot: the Unimate.

General Motors adopted the robot on their production lines in Trenton, New Jersey.

Devol continued to bring technology to life over the course of his career. He passed away at 99 years old on August 11, 2011.

How the Unimate changed the world of manufacturing

Thanks to Devol, the Unimate opened the doors for revolution in manufacturing. Industrial robots have been refined and expanded upon since the Unimate’s creation so that manufacturers of any industry can automate their facilities.

The industrial robots of today have far more applications compared to the Unimate’s limited offerings, including but not limited to:

Material handling
Painting
Machine tending
Picking and palletizing
Gluing, sealing, and spraying

Waterjet cutting
Assembly

Additionally, robots have made their way out of manufacturing and into other industries such as medicine. Surgeons use robots to assist with very delicate surgeries, such as head and neck or heart surgeries.

Additionally, hygienic robots have made a breakthrough during the COVID-19 pandemic, helping to keep hospitals, airports, and warehouses clean.

Because of the Unimate, the possibilities are endless for automation to create a brighter, cleaner, more productive future.

How to automate your facility

Are you new to automation, but you feel intimidated by all the options?

Don’t fret! NRTC Automation and our sister company, iGAM, are here to help.

NRTC can build a custom work cell to specifically for your production needs. We will design, build, engineer, and install the robotic work cell for you so all you need to do is turn it on!

With NRTC, automation is simple. We offer financing so you can automate no matter what size or phase you are in. Visit our Financing page to learn more.

iGAM offers standalone industrial robots as well. With top name brands like KUKA, FANUC, and ABB, you can be sure that your production line will be more efficient while reducing downtime on the warehouse floor.

Friendly iGAM Specialists are available to help you find what you need, including robot controllers, robot parts, and other manufacturing equipment. iGAM also provides financing for a pain-free transition to automation.

Need additional support after implementing robots into your facility? NRTC Automation offers full-service solutions to help you meet your production goals. From industrial robot refurbishing to robotic engineering, we’re your source for automation services. Visit our website to see everything we offer!

Together, NRTC Automation and iGAM are here to make automation accessible to all manufacturers. Work with us to start growing your company today.

VISIT NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Schedule a free consultation with NRTC! We will work with you to create a turnkey automation solution to meet your needs.

Jaydip Patel 2021-05-18 Jaydip Patel 2021-05-18

How Can You Adapt to Rapidly Changing Industrial Automation?

Manufacturing is changing. Industry 4.0 is advancing manufacturing with limitless opportunities for growth.

If you’ve been paying attention to the news, you’ve probably noticed two trends: COVID-19 and Industry 4.0.

Today, we’re passing up an analysis on the pandemic’s impact on the industry to discuss the Fourth Industrial Revolution. If you are a small- to mid-sized manufacturer, you may feel left behind in all this innovation. Thankfully, NRTC Automation is here to help!

Learn more about the digital revolution and how to keep up below.

Adapting to changes in industrial automation

Shifting from traditional to digital manufacturing

In the last 100 years, manufacturing has made some impressive leaps.

Innovations in the production line have improved productivity drastically, enabling manufacturing to put out more product and reduce waste.

When industrial robots hit the scene in the mid-20th century, the industry changed forever. Now, manufacturers could create uniform products in minimal time with fewer (costly) mistakes.

Today, the digital manufacturing revolution, or Industry 4.0, is revolutionizing the way manufacturers view data and production. With the help of AI and IoT, seeing the intricacies of the manufacturing process is easier than ever before.

What it means for manufacturing

Industry 4.0 is changing the face of manufacturing.

Digital information allows manufacturers and operators to enhance their production lines with limitless data. For example, if productivity drops slightly, an alert from IoT connected devices will notify the operator. Depending on the cause, the operator may choose to tweak the equipment to enhance performance. Better operational efficiency means a greater bottom line for your company and a more competitive stance in your industry.

Plus, digital manufacturing allows machines to communicate with each other, reducing the amount of labor needed from employees on the production line. Your staff can work more fulfilling and engaging jobs rather than working the line, which can be dangerous for their health. Less workers on the line means increased cost savings for you as well: a production line operated by one person saved an average of $120,000 every month.

Prototyping and 3D printing are also improved due to Industry 4.0. Now, because of additive manufacturing, manufacturers can design and create a prototype in a fraction of the time compared to traditional prototyping methods. Product development is sped up, getting your product to your customers sooner.

How to adapt to Industry 4.0

No matter where you are in your journey to automation, we suggest the following to stay up-to-date with the latest developments in digital manufacturing.

INCREASE CYBERSECURITY PRACTICES

Manufacturing is one of the most targeted industries for cyber attacks. With one fell swoop, hackers can destroy your internal systems and leak confidential information.

Can your company withstand a day, or even a week, without power to run your manufacturing facility? If not (and most companies cannot), then you need to strengthen your firewalls and other cybersecurity practices before you become a victim.

Check out our blog post here for ways in which you can protect your company and employees from malicious cyber threats.

ADD SMART DEVICES

Now is the time to invest in IoT.

Adding smart devices to your facility will put you in line with even the biggest competitors in your industry. Using the latest technology in IoT will enhance supply chain management so you can continue to optimize your production line for the best results.

USE YOUR DATA

Finally, use the data that digital manufacturing offers you.

Data is an extremely valuable tool that allows you to shift from a confusing and mismanaged warehouse to an efficient, streamlined production line.

Minimize downtime and increase productivity by making informed decisions on what changes to apply to your production line. The opportunity for improvement is limitless, so take advantage of data to enhance your manufacturing processes.

Start slow and get industrial automation support with NRTC

If you are a small- to mid-sized manufacturer who wants to grow, but you’re new to automation, then you’ve come to the right place.

We will help you meet your production goals and rise above the competition by adopting comprehensive and sustainable automation practices.

NRTC Automation offers full-service solutions to assist you from start to finish:

With NRTC, you can keep up with changes in the industry and improve your business in the process. We work with top auto manufacturers such as Toyota, Mercedes, and Ford, so you know you can trust us. Head over to our site to learn more about our decade of experience in the industry.

Plus, check out our YouTube video below to see more of our warehouse!

VISIT NRTC AUTOMATION TODAY

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

Schedule a free consultation with us today to get personalized automation strategies for your company.

Lydia Sanderson 2021-05-04 Lydia Sanderson 2021-05-04

How to Optimize Automation in Your Facility

Want to make the most out of your industrial robots? Use these five tips to improve productivity, minimize downtime, and increase throughput by optimizing automation in your facility.

Want to make the most out of your industrial robots? Use these five tips to improve productivity, minimize downtime, and increase throughput by optimizing automation in your facility.

Adding automation is only one step to success when growing your manufacturing company.

Even before adding industrial robots, such as KUKA robots or FANUC robots, as well as other automation equipment to your production line, there are ways to improve production so that once you add automation, it works as intended.

Learn more about how to optimize industrial robots and equipment in your production line below!

How to optimize automation in your facility

Implement these simple tips into your production line to get the most out of your industrial robots.

1. Create clear and concise end goals.

Knowing the end goal in your intention to automate is necessary to have a functional robotic production line. Are you automating just to stay on par with similar companies in your industry? If so, that will lead to a lack of foresight needed to know what needs to be automated (and what doesn’t!).

These are some questions that relate to clear, actionable goals that necessitate automating:

Do you want to cut down on time and reduce production waste?
Are there tasks in your business that are highly repetitive and would benefit by adding a robot, thus reducing human error?
Do you want to standardize your production process?

By taking the time to consider why you want to automate in the first place, you can understand what parts of the production process needed to be automated and how it will integrate into your workplace.

2. Add valuable staff to manage the production line.

Humans are integral to automation. When we work with automation, we can learn what is or isn’t working and improve our processes.

Automation is excellent for businesses because it produces data on your manufacturing process. You can find out where energy is being wasted, which tasks are time dumps, and more.

Have an employee or a team that checks on the status of your automation and data. They can come up with ideas that can save you time and money as your company grows.

3. Check for any missing components in your production line.

You don’t need a production line solely worked by robots in order to have a successful automated business. You do need a production line that is airtight and doesn’t have any gaps that may cause downtime or buildup.

Streamlining is the name of the business. When you automate, you should have a smooth production flow that has a step for every part of the process. Take the time to observe your production line in action and note what could be improved; ideally, look at the data from reason #2 and find out where you can make adjustments.

4. Get educated on industrial robotics and automation.

Automation is not limited to robots. When you automate your company, there are servo drives, pedestals, end-of-arm-tools, circuit breakers and circuit protection, productivity displays, and so many other components to industrial production that you must account for.

Each piece of equipment benefits the production line in a different way. Most of this equipment is necessary for the production line to function properly.

If you want to automate your business successfully, then getting educated on robotics and industrial equipment is a good way to start. Learn about the anatomy of an automated production line, or read more about the connection between servo drives and motors.

Every bit of knowledge will help you make better decisions when adding industrial automation to your manufacturing process.

5. Prioritize company-wide involvement and understanding of automation.

Last but not least, you might be failing at automation if your team doesn’t understand how it works.

When everyone understands the effort to automate and knows how their job relates to the robot in the production room, then automation can become a collaborative effort.

Working together to have a cohesive automated company will not only increase your chances of having a productive and efficient automated line, but it will also boost company morale and improve your work environment.

Bring everyone together for monthly lunches and update the team on the latest automated processes to fully integrate robotics into your company.

Improve your operations today using automation.

As industrial automation becomes more mainstream and technologies advance, the ability to automate your business gets easier. Plus, you have resources like NRTC Automation to help you build and improve your automation process so you can be successful from the beginning.

NRTC AUTOMATION WILL WORK WITH YOU TO AUTOMATE YOUR COMPANY.

Automating your business will allow you to be more efficient, reduce your production waste, and increase your revenue. Work with NRTC Automation, a trusted partner of top auto manufacturers around the world, to automate your company.

NRTC offers turnkey solutions such as building, designing, and engineering customized work cells that will seamlessly fit into your production line. We also train companies in robotics, repair industrial equipment with professional technicians, manufacture service parts, and more.

Schedule a free consultation here to get a personalized automation plan for your company.

Lydia Sanderson 2021-04-20 Lydia Sanderson 2021-04-20

Why Everyone is Obsessed with Industrial Robots

Automation is all over the news. NRTC discusses the hype and how you can jump into automation with us.

Automation is all over the news. NRTC discusses the hype and how you can jump into automation with us.

Coverage on industrial robots is growing, especially since the start COVID-19, as more industries are adopting automation to cope with new social distancing and hygiene mandates.

Are you curious about the direction automation is taking us? Read more about current predictions and how NRTC Automation can help you join the movement below.

The future of industrial automation

Industrial robots in the news

If you've been on news sites in the past decade, then you’ve seen articles and videos about industrial automation and robotics.

We won’t get into the myths of industrial robots here—we’ve already covered that topic in this blog post—but we are interested in discussing the recent boom in automation that everyone is talking about.

For example, Yaskawa Motoman recently became part of the 500k club, selling half a million robots over the course of the company’s history. FANUC is another robot manufacturer who surpassed the half-million mark.

Clearly, there is a demand for automation. Even though industrial robot sales slumped the past two years due to an economic downturn in 2019 and COVID in 2020, sales are beginning to pick up again.

Industries that use automation

Automation is the key to the future of manufacturing.

Other industries are also using automation to improve productivity, accuracy, and efficiency, such as:

Agriculture: Industrial robots and drones are used to plant, water, pick, and sort crops, reducing lead time from harvest to shipment and assisting with backbreaking jobs in the daily work of agriculture laborers.
Food preparation: Robots are making their way into the kitchen, to the relief of many who don’t love spending hours on meal preparation and cleanup. Check out Flippy the robotic burger flipper for some good old-fashioned robot entertainment.

Military and public safety: Robotic technology such as drones are being used by the military and public safety sectors. For example, with drones, rescue operations are made easier by improved visibility and access to hazardous areas caused by natural disasters.
Healthcare: Surgical robots are not new to the medical field. Doctors use them for increased precision during surgery. Additionally, and especially during COVID-19, robots are used to clean facilities by scrubbing the floor, emitting UV light, and other methods. Other industries, such as manufacturing, are using hygienic robots to maintain COVID-19 cleaning mandates.

As our world becomes increasingly digital, more industries are adopting automation to keep pace with changes in technology and public expectations.

Predictions about automation

For better or for worse, much of the buzz in the news about automation has to do with predictions of the future.

Common questions about automation include:

What industries will robots move into next?
How will businesses change in response to increasing automation?
How will automation affect human labor?
What are the potential security risks of increasing automation?

While some articles develop a doomsday scenario that robots will take over an overwhelming majority of human jobs, others negate that perspective. Industrial robots and other automation will handle repetitive physical labor and number-crunching work, but creative services, management, interpersonal work, and similar jobs will remain in the human realm.

Automation is progressing rapidly, and so are we. Changes in the labor landscape have been occurring for hundreds of years as innovations are made.

In response to advancements in technology, new jobs have been created, such as digital marketers, robot technicians, app developers, data scientists, and more.

Why you should start automating

In the manufacturing industry especially, industrial automation is the key to growth.

Benefits of adding industrial robots and manufacturing equipment to your production line include:

Increased scalability: Automation improves efficiency and minimizes downtime, getting your product to your customer sooner. You’ll be able to meet greater demand by cutting down on wasted time.
Improved workplace safety: As mentioned above, industrial robots take over the dirty, dangerous, and repetitive work that is notorious for causing musculoskeletal injuries.
Enhanced product quality: Robots are more precise, resulting in improved product quality. For example, robotic welders provide a clean and accurate weld every time so you don’t have to worry about unnecessary product recalls.

Adopting automation doesn’t have to be difficult. By using a service like NRTC Automation, you can be well on your way to competitive advancements in productivity and operation efficiency.

How to get started

Are you looking to jump into automation?

NRTC can guide you from start to finish. Our Automation Services will get you on the fast track to start increasing throughput and capacity in your facility. We’ll work with you to design, build, and engineer a custom work cell for your production needs.

We work with top auto manufacturers like Toyota, Ford, and BMW, as well as small- to mid-sized manufacturers looking to grow their businesses. With over a decade of experience, and with our professional engineers and technicians, we provide some of the best automation solutions in the industry.

Plus, we offer financing to make automation affordable for manufacturers of any size. Get ahead of the competition and start automating with NRTC today.

WORK WITH NRTC AUTOMATION TODAY

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.

Schedule a free consultation here and we’ll develop an automation plan specific to your company’s needs.

Jaydip Patel 2021-03-09 Jaydip Patel 2021-03-09

3 Signs That Your Robot Needs Repair

Taking care of your robot is easy when you practice preventative maintenance. However, there comes a point when your robot might need more for optimal performance.

Taking care of your robot is easy when you practice preventative maintenance. However, there comes a point when your robot might need more for optimal performance.

Industrial robots are the heart and soul of automation. They need to be in prime condition at all times to operate efficiently and effectively.

The best way to do this is through preventative maintenance. However, even the most well-prepared manufacturer will have to repair their robot eventually.

Learn more about the signs that your robot needs repair and how NRTC Automation can help below.

3 signs that your robot needs repair

Preventative maintenance

Across the board, preventative maintenance (or PM) in manufacturing is the number one way to protect your equipment, extend equipment useable life, and increase cost savings over time.

Every manufacturer should be proactive about PM. By rigidly adhering to maintenance schedules, business owners can see a 545% ROI on their equipment. You read that right! Although maintenance involves some costs of cleaning and replacing parts, the ROI is well worth the small price.

We can help maintain your equipment. You can choose your level of reconditioning based on the condition and hourly usage of the robot. NRTC Automation’s Industrial Robot Refurbishing Services will clean, grease, and test your equipment all the way up to a brand-new paint job and full robot restore.

Time for repairs

If your robot is older, or if you haven’t been diligent about maintenance, then it might be time for repairs.

While you may be tempted to skip the repair expenses, there are downsides to running your equipment into the ground:

Safety: This is the most important issue when considering maintenance and repair. When a robot isn’t functioning properly, it becomes unpredictable and could potentially hurt or fatally injure your employees.
Electrical damage: Electrical damage can occur in a malfunctioning robot due to worn cables and other equipment. This can create dangerous conditions on the production line.

Unplanned downtime: If your robot dies suddenly, the unplanned downtime can cost thousands of dollars a minute. And if you don’t have a technician in-house, getting someone in to fix it can take a while.
Product quality issues: Robots need to be in tip-top shape to ensure that your product is consistently made well. Without maintenance or repairs, your robot could potentially end up ruining hundreds or even thousands of products before you realize it.

Keeping up with your robots is a necessity for the well-being of your employees, your production line, and your bottom line.

3 signs that your robot needs repair

How do you know when it is time for a repair? Check out these three signs to determine if you need to get your robot to the nearest technician.

1. DOWNTIME

You’re doing everything you can to increase productivity, from implementing lean manufacturing methods to automating additional processes, but for some reason, your numbers just aren’t reaching the markers.

Have you checked how your robot is performing? If an industrial robot needs repair, then it could be contributing to your downtime. Faulty controls, software, and other systems can cause a robot to slow down and move erratically, wasting precious production time.

2. REPEATABILITY

Robots need to have highly repeatable applications to produce high-quality products. For example, if you have a welding robot, you want your welds to be precise and clean.

However, if your robot needs repair, your welds might come out sloppy, erratic, and generally unfit for consumer use.

Keep an eye on your robot’s output to ensure that it meets your standards. If not, it may be time to send it to the technician.

3. ENERGY EFFICIENCY

Finally, industrial robots should be as energy-efficient as possible. When a robot starts using a lot of energy, it is a sign that the parts aren’t working properly. Not only does this affect the overall productivity of the robot, but it is also a strain on your wallet.

Check on energy usage reports to determine where electricity and other energy sources are being used the most.

Get expert repair services at NRTC

NRTC Automation offers both Engineering Services to troubleshoot and diagnose your robot as well as Industrial Robot Refurbishing Services to maintain your equipment for a well-rounded automation experience.

Plus, our sister company, iGAM, provides refurbished robot parts and equipment so you can repair your industrial robot without breaking the budget.

Don’t delay fixing your equipment! Save on downtime and expensive product recalls by contacting NRTC Automation today.

VISIT OUR WEBSITE TODAY

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.

Schedule a free consultation with us to meet your production goals this year.

Lydia Sanderson 2021-03-02 Lydia Sanderson 2021-03-02

What Changed in Industrial Automation in the Age of COVID-19?

The whole world experienced a massive shift after COVID-19 struck. The manufacturing sector was no exception.

The whole world experienced a massive shift after COVID-19 struck. The manufacturing sector was no exception.

Before the pandemic, industrial automation was slowly growing into the 4th Industrial Revolution, or Industry 4.0. After the global shutdown, manufacturing and other industries were ushered into a new era of technology dependence.

Industrial automation became the hot topic of 2020. Manufacturers who previously used traditional production methods and survived the pandemic are highly encouraged to adopt automation to stay relevant with global competition.

Learn more about how COVID-19 changed manufacturing and industrial automation, as well as how you can automate your production line, below.

Industrial automation during the COVID-19 pandemic

COVID-19 rocked the world

When coronavirus started making headline news in February 2020 and shut down the world by March, researchers, publications, scientists, and other thought leaders surmised how a global pandemic might affect the manufacturing industry.

The outlook was a mix of positive and negative:

Some looked at the pandemic’s effects on the workplace and saw the perfect opportunity for industrial robots to maintain social distancing mandates and clean workplaces.

Others feared that the drops in profit and productivity at the beginning of the pandemic would forever scar the industry’s ability to bounce back.

There is truth in both of these predictions. Some manufacturing companies sunk because of COVID-19, unable to keep up with the struggles of closures, labor changes, and reduced demand.

However, this is a great moment for automation because it proves just how necessary industrial robots and equipment are to maintain our standards of living. During difficult and uncertain times, industrial automation allowed us to continue production while keeping workers safe.

Uncertainties abound

Even now, a year after the fact, there are still uncertainties around how life will look after COVID-19.

What will the “new normal” look like for the manufacturing sector?
Will industrial automation be handling even more processes than before?
Will employees shift to other labor like management, maintenance, and repair?
Will there be a resulting skills gap that is even larger than what manufacturing was experiencing before the pandemic?
What shifts will occur in IoT and cybersecurity to meet the new disparities and mitigate risks caused by these changes?

The answers to these questions will impact not only companies who want to continue growing during COVID-19, but also future manufacturing workers and the economy.

Hopefully, the insights gained from manufacturing’s weaknesses during the pandemic will provide industry leaders—as well as small manufacturers and their employees —with the opportunity to improve production processes and offer a better workplace and product all around.

Why you should automate during the pandemic

If you are a manufacturer struggling during the pandemic, we understand your concerns. You have survived one of the toughest fallouts in manufacturing since the Great Depression and the 2008 Great Recession. However, studies report that manufacturing has bounced back to pre-COVID levels and continues to look up into the spring.

Now is the time to act: automate your processes and keep up with the global competition. Manufacturers around the world are jumping on the Industry 4.0 bandwagon. If you continue with traditional manufacturing practices, you may find yourself on the outskirts of consumer demand.

Finance automation with us

Cost is always a concern, and NRTC Automation kept that in mind when designing automation solutions for our customers.

For those looking to automate specific production capabilities at an affordable price, robotic work cells offer the competitive advantages of an all-in-one package including:

maximum compatibility between components
increased efficiency
improved safety

Not only do we provide affordable custom work cells by using refurbished industrial robots and equipment, but we also offer financing so manufacturers of any budget can automate their warehouse.

To learn more about our financing options for your specific automation needs, schedule a free consultation with NRTC Automation. We’ll go over the cost, design specifications, engineering, and installation questions you may have about your custom work cell.

DON’T JUST SURVIVE, THRIVE WITH NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.

Contact NRTC today to meet your production goals during these challenging times.

Jaydip Patel 2021-02-15 Jaydip Patel 2021-02-15

5 Methods for a Lean Manufacturing Process

Lean is the way of the future. Get on top of your production waste by trying out one or more of these lean manufacturing methods.

Lean is the way of the future. Get on top of your production waste by trying out one or more of these lean manufacturing methods.

Manufacturing continues to change with technology and new ideas, and so manufacturers need to stay abreast of these innovations to remain competitive in their industry.

Lean manufacturing is one of the most important developments in manufacturing history, and it continues to inspire big-name manufacturers like Toyota today.

To start going lean and improve your production processes, learn more about the history of lean and popular methods below.

Using lean manufacturing methods

What is lean manufacturing?

Lean manufacturing is a methodology that applies practices and principles to reduce waste, minimize downtime, increase cost savings, and produce sustainably.

Although there is evidence of lean manufacturing methods back in the 15th century, the first real application of lean was in Henry Ford’s production line in 1913. In the 1930s and after World War II, Toyota led the world in lean manufacturing, providing monumental lean philosophies such as 5S.

Since then, lean manufacturing has developed into innovative philosophies that have changed how we manufacture today.

Benefits of going lean

The reason why manufacturing companies continue to use lean methodology is because of the numerous benefits it provides. Some of these benefits include:

Reduced lead time: Efficient manufacturing reduces lead time, shipping your product out faster for higher customer satisfaction.
Improved product quality: Product quality is improved when wasted motions and materials are removed. Like Antoine de Saint-Exupery said, “Perfection is achieved, not when there is nothing more to add, but when there is nothing left to take away.”
Less product waste: As mentioned, lean manufacturing reduces product waste by removing unnecessary materials during the manufacturing process.

Minimal downtime: Less time is wasted during lean manufacturing since processes are more efficient.
Increased cost savings: Because product quality is improved, downtime is minimized, and fewer materials are wasted, manufacturers see an increase in cost savings when they go lean.
Sustainability: Lean manufacturing is far more sustainable than traditional manufacturing, which is a necessity for consumers who demand better from companies.

To reap the benefits of lean thinking, learn five different methods of lean manufacturing below.

5 methods for a lean manufacturing process

1. KANBAN

The purpose of Kanban is to manage workflow processes in a visual manner. Kanban is Japanese for “sign,” and it was developed by Toyota in the 1940s.

In order to add Kanban thinking to your production line, start implementing visual cues of the progress of your products on the warehouse floor. This could be a digital board or a physical board that includes categories such as “Ready to Start,” “Working,” “Waiting,” “Review,” and “Done.”

2. KAIZEN

Kaizen is a form of Japanese business philosophy meaning “continuous improvement” or “change for the better." This lean method focuses on holistically improving product quality, company culture, and production efficiency.

It is a cycle of progression that constantly analyses production inefficiencies to improve manufacturing. By tracking and measuring progress, manufacturers can create leaner production lines.

3. CELLULAR MANUFACTURING

Cellular manufacturing is applied to the layout of the manufacturing floor. It is the strategic arrangement of equipment and processes to reduce waste.

Before cellular manufacturing, the flow of production was jumbled up, jumping around from one place to another throughout the plant. Now, manufacturers use cellular manufacturing to provide a seamless workflow through layouts such as the U-shape, straight line, or inverted U-shape.

4. 3P

The Ps of 3P stand for Production Preparation Process. By eliminating waste through prototyping, manufacturers can improve product quality and minimize downtime on the production floor.

NRTC Automation provides prototyping services to help you create a leaner company. Reach out to us here to learn more about what we can do for you.

5. 5S

Last but not least, 5S is another popular method of lean. It stands for Sort, Set in Order, Shine, Standardize, and Sustain. This method of lean manufacturing also originated in Japan and centers efficiency around necessary versus unnecessary processes.

It’s similar to adding key hooks near your front door so you don’t lose your car keys. By putting everything in its place, manufacturers can reduce downtime and improve productivity.

Stay competitive in 2021 by getting leaner

To stay competitive in your industry, start implementing more lean methodology into your manufacturing processes. Not only will you see an increase in cost savings and productivity, but you’ll have happier customers and greater demand for your product.

OPTIMIZE YOUR PRODUCTION LINE WITH NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.

Schedule a free consultation with NRTC to learn how we can free up time and resources on your production floor.

Jaydip Patel 2021-02-08 Jaydip Patel 2021-02-08

How to Hire Experienced Technicians for Your Business

Manufacturing may be in a hiring slump, but with these tips, you can find the right technician for the job.

Manufacturing may be in a hiring slump, but with these tips, you can find the right technician for the job.

Hiring is a risky business. It takes time to find qualified people for a job, and if you choose the wrong person, the results can be disastrous.

And that’s not to mention manufacturing’s current worker shortage.

Learn how to overcome these barriers to recruiting and hiring technicians below.

How to hire experienced technicians for your business

Difficulties of hiring in manufacturing

There is a shortage of qualified workers in manufacturing.

By 2030, the manufacturing industry will be short of 2.5 million workers. These hiring challenges create gaps in the workplace, making it difficult for manufacturers to meet their production goals.

The COVID-19 pandemic hasn’t helped, either. People fear unemployment during these uncertain times and are searching for industries with lower unemployment rates.

Despite common public fear, automation cannot take over everyone’s job. We need experienced, qualified individuals to help run our manufacturing facilities.

Importance of finding quality employees

Hiring Joe Schmoe off the street may close the gap in your production line, but it could cause far more pervasive issues throughout your facility.

Hiring unqualified workers can lead to these problems:

Lower product quality

Machine failure due to improper use or maintenance
Increased lead time
Unplanned downtime
Work-related issues between employees

That’s why it’s important to find the right people for the job. You can save hundreds of thousands of dollars on unplanned downtime or product recalls by taking the time to select experienced individuals.

Steps to find experienced technicians for your business

If you are in need of technicians on the warehouse floor, take these four steps.

1. GET CREATIVE.

Dump the traditional recruiting methods like local paper advertisements for modern methods:

Social media advertising: Get on platforms like Facebook, LinkedIn, and Twitter to advertise your job. If you already have a following, you can target people who have already expressed interest in your company. If you don’t, create an account and start building your online presence with a job offer!

Online job boards: People have moved online to search for everything, from employment to housing. Post your job on sites like Indeed to reach an expansive audience.
Events: Since COVID-19, group gatherings have been limited and require face coverings and social distancing. However, if gatherings are allowed in your area, then host a hiring event! You’ll meet your applicants face-to-face and get a better idea of the people you are targeting.

These newer forms of job recruitment may be foreign to you, but they provide an easier way to access more people, including people who are qualified and interested in your job.

2. OFFER INCENTIVES.

Does your company offer a 401(k) match? What about free lunches on Fridays or parental leave?

All of these incentives will drive applicants to your job. People want to work in a place that honors their needs and wants.

If you don’t currently offer incentives such as the above, then start looking into some that your company can afford. Not only will you drive more traffic to your job application, but your current employees will be compelled to stay longer as well.

3. ASK THE RIGHT QUESTIONS.

You’ve gotten some applications and you are ready to interview. This is the hard part.

Know the right questions to ask, and how to ask them. Don’t give applicants an easy way out with a leading question. For example, "You’ve worked on KUKA robots, haven’t you?” is a leading question because it suggests that the applicant should say yes. Use open-ended phrasing like “What robots have you worked on in the past?” to get an accurate answer.

Additionally, be sure to ask questions that probe both hard and soft skills. You don’t want to hire someone with brilliant technical skills but lacks any communication skills. You can ask scenario-based questions to determine how a person will work with other people.

4. BE OPEN TO TRAINING THE RIGHT PERSON.

If someone checks nearly all your boxes, but they are missing one vital skillset, then consider training them. Putting time and resources into an employee who meets your criteria is a long-term investment.

For example, they may be highly capable at debugging and troubleshooting, but need help learning how to perform robot cleaning and degreasing. Training your employees will provide them with new skills and show them that you want them to stay in the company.

NRTC Automation offers Robotic Training Services to get your staff on the right track. Learn more about how we can tailor our training to your company here.

Start looking for the right personnel for your company

The best time to start recruiting is now. Take advantage of the tips listed above to find the right person for the job.

If you need technicians but lack the resources to recruit, NRTC Automation can help! Our Engineering Services will recruit, interview, and hire qualified technicians. We make it easy for you to finish the job with the right personnel.

Learn more about our Engineering Services today.

GET HIRING HELP FROM NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.

Schedule a free consultation with us to learn more about how we can help you achieve your production goals.

Lydia Sanderson 2021-01-27 Lydia Sanderson 2021-01-27

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.

3D printing is a booming market: in 2018, over 3.3 billion dollars of revenue was generated with 3D printers by companies in the United States.

If you don’t have a 3D printer on your production line yet, consider the advantages of having one on the blog: https://t.co/Nx0ulQ9kMG pic.twitter.com/lMpGMWtWpW
— iGAM Marketplace (@igammarketplace) July 6, 2020

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.

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