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Sirris manufacturingday2011 flexible-robotising-robo_job

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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.

Veröffentlicht in: Technologie, Business
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Sirris manufacturingday2011 flexible-robotising-robo_job

  1. 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 9/05/2011 1Helmut De Roovere
  2. 2. Aluro-Group companies  Reception  General. IT-infrastructure  Accounting & Finance  ReportingEasily 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 9/05/2011 2 Helmut De Roovere
  3. 3. 9/05/2011 3Helmut De Roovere
  4. 4. Our customers work in International markets  Competition on international level  Prices dictated by a global market  Benefits & Handicaps when producing in Belgium  …. 9/05/2011 4Helmut De Roovere
  5. 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, …. 9/05/2011 5Helmut De Roovere
  6. 6. Internal capacity mechanical parts RecourcesMarket 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 9/05/2011 6 Helmut De Roovere
  7. 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 9/05/2011 7Helmut De Roovere
  8. 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 9/05/2011 8 Helmut De Roovere
  9. 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 yearsMARKET CHANGEMENTS ARE DRAMATIC Solution is urgent needed 9/05/2011 9Helmut De Roovere
  10. 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 9/05/2011 10Helmut De Roovere
  11. 11. Integrated Robot System-Chuck Work 9/05/2011 11Helmut De Roovere
  12. 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 9/05/2011 12Helmut De Roovere
  13. 13. Results within normal working hours when making small & medium batches 1995 2010 2011 + RoboJobMarket tariff CNC 60,- €/h 60,- €/h 60,- €/hLabour cost operator 22,- €/h 38,- €/h 13,- €/h Only for Set-upDepreciation of CNC 12,- €/h 12,- €/h 12+6=18,- €/h Additional depreciationTooling cost 5,- €/h 5,- €/h 5,- €/hGross 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 9/05/2011 13Helmut De Roovere
  14. 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% 9/05/2011 14Helmut De Roovere
  15. 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 yearIRS-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 9/05/2011 15Helmut De Roovere
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  17. 17. 9/05/2011 17Helmut De Roovere

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