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Machine tending

jaka cobot machine tending application

Machine Tending I Automotive Industry

Cutting and Milling Machine Tending by JAKA Pro 12 Cobots

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Industry

Automotive

Application

Machine tending

Integrated Cobots

JAKA Pro 12

Total number of cobots

56

About the Company

The company focuses on the manufacture of auto parts and accessories. It produces and sells isokinetic belts, and provides an after-sales service for additional auto parts and products.

Company’s Challenges

The company had been operating a production line with 119 cutting and milling machines for some time, and had come to the decision that it was a good time for an upgrade.

The existing system required 60 specialists to work with the machines, across five machine tending areas, each of which made for relatively harsh environments. The specialists had to endure high levels of noise, a tight working space, and health and safety risks.

The company wanted to mitigate some of these factors, while reducing insurance, electricity and water costs, all the while improving the production cycle time.

While the process had already been automated to some degree, an evaluation of the latest automation technologies suggested that with the help of cobots, it could be fully automated. Such automation would also allow for an expansion in the number of machines utilized, thereby increasing production capacity.

Machine Tending I Automotive Industry

Solution

For this project, a total of 56 JAKA Pro 12 collaborative robots (cobots) were installed. With the help of a cobot integrator, they were set to service 119 cutting and milling machines, across all five areas of machine tending. The effects of the harsh environment were mitigated by the JAKA Pro 12’s IP68-grade protection, meaning it is immune to dust, water and oil.

The company were clear about their expectations for constant production, and therefore chose cobots that can operate 24 hours a day, for 50,000 hours – almost six years – without interruption.

The cobots were set to work on the machining of various products, such as rotary inner hooks, intermediate shafts, three-pin shafts and more. The huge range of end effectors on offer meant that handling these items, despite their often smooth surfaces and idiosyncratic shapes, was no problem.

The integration of the cobots onto the production line took around a week, with each machining area taking around a day and a half. After integration was complete, the company wanted to make some small adjustments. Thanks to the drag teaching and graphical programming capabilities of the cobots, employees of the company were able to complete these adjustments without the need for a skilled integrator.

Results

The results were that each of the challenges outlined in the initial review of the situation were solved for.

  • Overall mobility increased from 90% to 98%, and production cycle time was reduced by 20%.
  • Whereas before shifts took place five days per week, production is now possible seven days a week, increasing capacity and efficiency.
  • In terms of ROI, the company expected the payback period to last two years, but in fact it lasted only a year and a half. This was helped by additional savings made on electricity, water and services/products involved in keeping human workers comfortable.
  • More than 60 workers gained the opportunity to upskill, to develop their career further with the help of specialized automation knowledge, or to focus on more complicated, creative tasks. As a result, the rate of staff turnover was reduced.
machine tending application by jaka cobots

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+86 400-006-2665
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Address

Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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jaka cobots machine tending automation project

FPC Machine Loading and Unloading

FPC Loading and Unloading by JAKA Zu 12 Cobots

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Industry

3c electronics

Application

Loading and unloading

Integrated Cobots

JAKA Zu 12

Total number of cobots

6

About the Company

One of the largest flexible printed circuit manufacturers, assemblers and suppliers across the globe. We strive to target our solutions within the electronics market and focus on applications where flexible printed circuits are the enabling technology in achieving a desired size, shape, weight or functionality of an electronic device.

Company Challenges

In the production of printed circuit boards (PCBs), one of the standard processes is screen printing. For this, the company utilizes large printing machines that can process two panels of flexible printed circuit (FPC) material at a time.

The process of loading and unloading the FPC to and from the machine was deemed by the company to need improvement for a few reasons.

  • First, the set capacity for one day of work was around 2,000 pieces, which was insufficient to fulfil all the orders that were being received.
  • Second, the conditions for the workers loading and unloading were not ideal – it was a yellow-lit area, with a strong odor of ink, and the repeated lifting of the FPC panels was physically demanding. This led to a high turnover of staff, which meant for additional costs in training.
  • Third, because of the high staff turnover, and the repetitive nature of the task, the production process was inconsistent, and errors were common.
jaka cobots machine tending automation project

Solution

The solution was to automate the task, and for this, the company chose to integrate six JAKA Zu 12 cobots. Fitted with suction cup end effectors, they are able to easily transfer two panels at a time from the supply area, into the machine, then back out of the machine onto a storage rack after printing. They’re able to carry out this operation 24 hours a day, 365 days a year.

  • The cobots were chosen instead of traditional industrial robots for several reasons. One is their size – compact and light, they were easy to mount in the middle of the three zones of operation (supply, machine, storage), and navigate between them in a compact space.
  • Another is their safety features. The factory floor is a collaborative zone, where humans work alongside the robots and machines. Thanks to an in-built torque feedback module, the JAKA Zu 12 cobots don’t need safety fences, they cease operation upon the detection of any collision, ensuring the safety for those nearby.
  • Finally, the cobots’ flexibility. They were installed and operational in less than a day, and can easily be re-assigned to new tasks by in-house employees if needed.

Results

  • Thanks to the six cobots installed, twenty employees that were formerly saddled with manual work are now able to focus on more creative, intellectually fulfilling tasks. Further, half of them who previously had to work night shifts are now able to work days, ensuring a better quality of life overall.
  • After automation, production capacity rose by 20%, the problem of high staff turnover was solved, less money and time needed to be spent on training, and production became consistent and error-free.
  • The return on the investment was quickly earned, with a payback period of less than two years.

For 3C electronics companies these affordable, compact, safe cobots are providing a competitive advantage in the production of high quality, high quantity goods.

jaka cobots pcb machine tending project

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Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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cobots for pcb loading and unloading

PCB Loading and Unloading

PCB Loading and Unloading by JAKA Zu 12 Cobots

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Industry

3c electronics

Application

Loading and unloading

Integrated Cobots

JAKA Zu 12

Total number of cobots

9

About the Company

One of the largest flexible printed circuit manufacturers, assemblers and suppliers across the globe. We strive to target our solutions within the electronics market and focus on applications where flexible printed circuits are the enabling technology in achieving a desired size, shape, weight or functionality of an electronic device.

Company Challenges

In the production of flexible printed circuit (FPC) boards, know also as printed circuit board (PCB), manufacturer identified one task that could be optimized through automation.

It involved loading and unloading circuit boards to and from a sliding PLC machine for stripping, and then stacking stripped boards in layers with protective paper.

There were nine workers, working across 18 machines, who completed 450 pieces per day. Due to the repetitive and physically demanding nature of the task, production efficiency was low, workers’ safety was at risk, there were human errors, and there was an inconvenient rate of staff turnover.

cobots for pcb loading and unloading

Solution

To automate the FPC loading and unloading process, the company chose to purchase nine units of the JAKA Zu 12 cobot. Cobots were chosen over traditional industrial automation robots due to their short payback period, high precision and accuracy.

In the case of the Zu 12, they were also valued for how compact they are – it was easy for them to fit within the space of the existing equipment. With the help of professional cobot integrators, their deployment took only a few hours.

Each cobot now follows the following procedure: first, it takes a printed circuit board (PCB) from an unprocessed stack and places it onto the stripping machine’s loading platform, a PLC slider. While the PCB is being stripped, the cobot transfers a sheet of protective paper from the unprocessed stack and deposits it on top of the processed stack.

Once the PCB has been stripped, it loads it onto the protective paper, on the processed stack, and begins the process again. Each cobot is able to carry out this operation, with no errors, 24 hours a day.

Results

The company management’s feedback was very positive. Thanks to the nine cobots, production efficiency immediately rose 15%.

They were able to free up human workers to focus on safer, more creative tasks, leading to a reduction in staff turnover. It was reported that the workers now feel more valuable, and less tired, as they no longer have to lift heavy objects eight hours per day.

pcb loading and unloading cobots results

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Info

+86 400-006-2665
marketing@jakarobotics.com

Address

Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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jaka cobot tending application on assembly line

Loading and Unloading on 5G Antenna’s Assembly Line

JAKA Cobots I  Loading and Unloading of 5G Antennas’ Details

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Industry

3c electronics

Application

Loading and unloading

Integrated Cobots

JAKA Zu 12

Total number of cobots

3

About the Company

One of the world’s largest Electronics Manufacturing Services (EMS) Company by revenue and a Global Fortune 500 company. Its operations span across 30 countries.

Company Challenges

After reviewing their production practices, areas for improvement in a particular the company’s loading and unloading task were identified.

The task involved transferring a selection of components, in sequence, between racks, dispensing machines, testing areas, screwing machines and output platforms.

To do this, one person had to be at each station, and to maintain 24/7 production, a day and a night shift rotation was necessary.

The efficiency of the staff was low; due to the repetitive, dull task, they grew tired and unfocused quickly.

There was also significant employee turnover, requiring frequent, time-consuming training. The employees who worked on the task were at a risk of injury, due to the heavy components and repetitive physical work.

Finally, due to the epidemic situation, having large numbers of people flowing through the factory floor was ill-advised, as an outbreak would lead to a cease in production.

jaka cobots for electronics assembly line automation

Solution

In order to balance manpower with automation, and relieve employees of certain risk factors, the company chose to integrate three JAKA Zu 12 collaborative robots at one assembly work station.

By working together, and dynamically switching end effectors, the cobots were able to adopt the processes independently, performing all the loading, unloading, pick and place tasks necessary.

This freed up the human workers to monitor quality control, and focus on more creative, less physically risky tasks.

Results

The three JAKA Zu 12 units installed at the one assembly station increased the production capacity by 15%. As a result of their integration there was a reduction in staff turnover, and a reduction in the flow of people across the factory floor, reducing the chances of an outbreak-induced halt to production.

The intensity of work for the human workers was reduced, and working collaboratively with the cobots meant the efficiency increased. The full payback period for this installation was less than two years.

jaka cobot tending application on assembly line

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Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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sandblasting machine tending cobots

Sandblasting Machine Tending

JAKA Cobots for Sandblasting Machine Tending

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Industry

3c electronics

Application

Machine tending

Integrated cobot

JAKA Zu 12

Total number of cobots

8

About the Company

A leading worldwide technology manufacturer providing critical components for IoT intelligence, with a special focus on Telecommunication Equipment and Metal Precision, LED technologies and Interconnect solutions.

Company Challenges

Part of the company’s production line involves using rotary indexing turntables for sandblasting metal components. Components are first loaded from an external input conveyor onto an indexing turntable, which is integrated with several others on a larger turntable.

The turntable rotates into a sandblasting cabinet, then rotates out once sandblasting is complete. The component is picked up, shaken clean of dust, then unloaded onto an output conveyor, making space for the next component. It is a repetitive and high-intensity task that results in a dusty, noisy environment.

Previously, it required six workers per shift, for whom the job was physically demanding, presented health risks, and was conducive to errors. The company decided to seek out robotics solutions, looking to find an affordable automated system that could work 24 hours a day.

Because of a limited budget, and the need to have as little downtime as possible, the solution had to be a robot that could be configured and reconfigured adaptively, during the working process.

Solution

Due to limited working space around the workstations, traditional industrial robots were not sought out. Instead, flexible, compact robotics arms were sought. They needed to be able to work both independently and integrated with other manufacturing equipment when needed.

To meet their requirements, in terms of flexibility and payload, in order to service four machines, JAKA suggested implementing eight JAKA Zu 12 units.

With the help of a professional cobot integrator, two units were assigned per machine. One was programmed to completed the task of loading from the input conveyor, while the other was set to the post-processing tasks of shaking the component clean of dust, then unloading to the output conveyor.

Results

  • Once the cobot integration was complete, the sandblasting production line was fully modernized to the company’s satisfaction.
  • Not only did it mean that employees were kept safe, but it increased efficiency, as the machine tending – loading and unloading – could be carried out 24 hours a day.
  • To the company’s surprise, the electricity bill was lower than before, as there was no longer the need to regulate the temperature of the working area in line with what is comfortable for people.
  • Another cost reduction after the cobot installation was the elimination of insurance payments for those employees who had to work long day and night shifts.
  • All this contributed to an ROI that was higher than the company had predicted, resulting in a payback period of less than two years.
sandblasting machine tending cobots

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Info

+86 400-006-2665
marketing@jakarobotics.com

Address

Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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jaka cobot loading of mobile screens

Loading and Unloading

JAKA Cobots for Loading and Unloading of Mobile Screens

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Industry

3c electronics

Application

Loading and unloading

Integrated cobot

JAKA Zu 3

Total number of cobots

1

About the Company

A leading worldwide technology manufacturer providing critical components for IoT intelligence, with a special focus on Telecommunication Equipment and Metal Precision, LED technologies and Interconnect solutions.

Company’s Challenges

For a company working in 3C electronics manufacturing, efficiency and accuracy are key. Areas of production that require repetitive, dull procedures present a much higher level of risk in both of these areas when tasks are carried out by humans.

For the company, there was one particular task on the assembly line that was reliably producing errors. The task was simple: taking a phone screen from a conveyor belt, placing it on a loading platform inside a laminating machine, waiting for the laminating machine to present a fresh loading platform, and then doing the same, again and again. It required two shifts for two people.

Solution

Deciding to automate the process, thereby freeing up the human workers to perform a task that’s less repetitive, the company chose the JAKA Zu 3 collaborative robot. There were a few motivations behind this decision:

1st – small footprint and flexibility. Unlike much traditional automation equipment, the Zu 3 is compact and light, and can be installed on virtually any stable surface. The space around the workstation was very tight, and transferring the phones from the conveyor to the laminator required a flexible, extensible arm.

2nd – ease of use. The company was mindful that with time, tasks like this may change slightly, and the configuration of the robot would need to easily adapt. The JAKA Zu 3 was chosen because it is easy to teach. Any operator, with or without prior programming experience, can assign new tasks simply by dragging the arm to desired positions, and using an APP with an intuitive interface to record the process.

3rd – fast payback. With two workers, and two shifts per day, this task was not low-cost. By adopting the use of the cobot instead, the company would have a payback period – the time needed to make up for the initial investment – of under a year.

 After integrating the cobot, the operation now follows these steps: first, the cobot picks up two screens from the conveyor, holds them over a camera for automatic inspection, then places them on the loading platform, and returns to the original position, ready to go again.

Results

  • While it was calculated that the payback period would be less than a year, it in fact took significantly less time than expected. It took only seven months
  • The two employees were freed up from manual, repetitive work to focus on more creative and intellectually fulfilling tasks
  • The cobot was able to increase efficiency and eliminate errors, as is vital for the 3C electronics industry

Looking for cobots to automate repetitive tasks?

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Your opinions are important to us. Whether it is a simple question or a valuable suggestion, we are here 24/7. You can call us by phone or email us directly.

Info

+86 400-006-2665
marketing@jakarobotics.com

Address

Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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