Demonstrated with the example of the „production of wing bolts”, automation saves costs also in standard application processing. In addition to economical aspects further advantages in terms of quality and logistics arise.
Wing bolts are produced by encapsulation of metal threaded pins. Conventionally, such inserts are placed in the mould manually by the operating personnel. The ensuing continual interruptions in the production process are eliminated by the use of a robotic system, achieving a continuous process.
The complete production process begins with automatic separation of the threaded pins, supplied in bulk. Separation is performed via a vibrating spiral conveyor with a straight section where the inserts are positioned according to the relevant cavity separation distances. From here, two pairs of inserts are picked by the gripper of the MULTILIFT and inserted in the four-cavity mould following removal of the finished moulded parts (also by the gripper). During the next injection moulding cycle, the four removed finished parts fall into the tubular bag via the chute through a swivelling motion of the robotic-system axis; the plastic film bag is printed prior to filling.
A comparison of the percentage distribution with regard to unit costs reveals a significant divergence in terms of machine and personnel costs. Personnel costs can be significantly lowered through the use of an automated facility, whereas the machine costs are correspondingly higher.
The calculation of unit costs, based on an annual quantity of 1,000,000 units reveals a significant savings potential in the case of the automated facility.
In terms of production time, the break-even point is reached after only 49 production days. Assuming a total order quantity of 1,000,000 units, the automated facility achieves a time saving of 46% compared to the conventional facility.
The calculations are based on a total utilisation period of only two years.
