The smart automated loading and unloading of work centers allows for manufacturing of small runs with reduced workforce. Operators spend time on more value-adding activities. Knowledge of robotics is not a prerequisite. A vision on the intelligent transformation towards flexibility and adaptivity of typical Belgian suppliers.

1. Flexible Robotizing for small and medium
sized runs
 Brief introduction Aluro Group company’s
 Analyses of the evolution making industry = genesis of
RoboJob
 List of requirements
 Illustration of our results
 Q&A
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2. Aluro-Group companies
 Reception
 General. IT-infrastructure
 Accounting & Finance
 Reporting
Easily automate your CNC Subcontractor Mechanical parts Equipment insulating profiles Bending Alu-profiles
www.robojob.be www.aluro-cnc.com www.aluro.com www.bestbend.com
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4. Our customers work in International markets
 Competition on international level
 Prices dictated by a global market
 Benefits & Handicaps when producing in Belgium
 ….
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5. Industry 2011 = Supply chain
Small variations by the end consumers lead to amplified variations every
step downwards the supply chain
Production companies must be SUPER flexible, smaller lotsizes, rapid
manufacturing of prototypes, shorter lead times, ….
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6. Internal capacity mechanical parts Recources
Market demand Machine capacity
Overtime, weekendwork, work during
vacation, recruitment, (over-) 24h x 360 days = 8640 h
investments,…STRESS
Tempory unemployment,
Operator capacity
dismissals, insolvency,…STRESS
14h x 220 days = 3080 h
Time
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7. a glimp at our labour market
Gross added value per person Productivity upcoming economies
Schrink of our working population Evolution of labour cost in Industry
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8. Evolution of Gross margin
1995 2010
Market tariff CNC work 60,- €/h 60,- €/h
Labour cost CNC operator -22,- €/h -38,- €/h
Depreciation of CNC machine -12,- €/h -12,- €/h
Tooling cost -5,- €/h -5,- €/h
Gross margin 21,- €/h 5,- €/h
• Over a period of 15 years, decline of gross margin by 76% !!!!!!!
• Attempt to compensate this by having one operator servicing more machines
• This is harder & harder to achieve by rapidly changing volumes & rising product
flexibility
• Consequences are , increasing pressure on production companies and their workers
• As this tendency is rising, our work environment becomes more & more unappealing ,
• Attempt to maintain gross margin by working longer with machines, or working with
only second hand machines
• Doing so is only a temporary solution, on a longer term this is pernicious
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9. Summary of analyse
+ Supply chain demand for great product- & volume flexibility
+ Our production output is based & depending on labour
+ Labour is not flexile, expensive and hard to get
+ Our labour population is general declining
+ Our labour cost is too high
+ Our productivity seems to stagger, we’ve reached the limits
+ Our gross margin declined with +70% over the last 15 years
MARKET CHANGEMENTS ARE DRAMATIC
Solution is urgent needed
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10. Our goal at RoboJob
Small & medium lot-sizes
2010
Market tariff CNC work 60,- €/h
30% is set-up related
Labour cost CNC operator -38,- €/h
Depreciation of CNC machine -12,- €/h
Tooling cost -5,- €/h 70% is related to
Gross margin 5,- €/h
production output
We aim to cut this labour factor
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11. Integrated Robot System-Chuck Work
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12. What we developed …
 Easy to integrate on existing CNC machines
 Usable for a RANGE of products (cfr. Range of CNC)
 Compact solution, workspace = limited & expensive
 CNC easy accessible for operator
 Very short set-up time < 5 minutes for new product
 Set-up by CNC operator NOT by Robot programmer
 Re-usable on other machines
 Re-usable when extending to decentralized automation
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13. Results within normal working hours
when making small & medium batches
1995 2010 2011 + RoboJob
Market tariff CNC 60,- €/h 60,- €/h 60,- €/h
Labour cost operator 22,- €/h 38,- €/h 13,- €/h Only for Set-up
Depreciation of CNC 12,- €/h 12,- €/h 12+6=18,- €/h Additional depreciation
Tooling cost 5,- €/h 5,- €/h 5,- €/h
Gross margin 21,- €/h 5,- €/h 24,- €/h Back in business !!
 In a 2 shift environment; 220 working days x 7,6h per shift= 3344 h per machine per year
 30 % of operator time is set-up related = 1003h/year
 Remaining time = production time (3344-1003=) 2341
 During this production time you can create extra gross margin of (24-5=)19€/h
 On a year this is extra gross margin of 44.479,-€ per CNC machine
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14. Possible extra results, nights, weekends,
NO vacation,…
 220 working days x 8 h per night = 1760 u per machine per year
 44 workweeks x 2 weekend days x 24 u = 2112 u per machine per year
 Total additional intrinsic capacity = 3872 u per machine per year
 This is more than during normal working hours 3344) !!!!
Possible additional gross margin
140,000 €
120,000 €
100,000 €
80,000 €
60,000 €
40,000 €
20,000 €
0€
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
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15. An industrial Robot is a durable resource :
 The utmost flexible automation component
 A proven uptime of 99,99%
 A proven life expectancy of + 15 year
IRS-CW system is a durable resource which :
 Even by small- & medium sized batches
 Can be put at work immediately WITHOUT SPECIFIC ROBOT KNOWLEDGE
 Set-up time < 5 minutes for new parts, < 3 minutes for repetitive parts
 Disconnect invoice hours from labour hours (70% disconnection by small & medium s.)
 Takes away production pressure from operators , this brings peace in your company
 Multiply your gross margin by 3 during normal working hours
 Immediately makes your potential capacity available in a structural way
 Guaranteed pay-back time < 2 years within normal working hours
 Potential pay-back time of 6 months
 Can be put at work 24h/day , 7 days a week
 Works for free after 5 years
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