MAY 20238MANUFACTURING TECHNOLOGY INSIGHTS8IN MY OPINIONBy Martin Høgsbjerg, Head of Supply Chain Technology, Danfoss Drives [NYSE : SHS]There are many contributing facets behind the increasing use of robotics in the factory, but three of them stand out, in particular: · Healthier working environment for staff· Improved quality in the manufacturing process· Reduced manufacturing costsAt Danfoss, we invest extreme efforts in achieving these benefits using robotics. And to do that we have overcome some big challenges. There is no easy way to establish and run a world-class manufacturing facility. It demands constant attention to new development and active participation in international robotics forums and development projects, to ensure Danfoss is always operating at the cutting edge of automation technology. This effort is also required to ensure that we implement automation at a responsibly safe level of maturity. In collaboration with international experts, we constantly keep up with the reliability limits of automation and apply them in the best way possible to our production of AC drives.The best thing about robots is also the worst Robots perform exactly the same action every time. This is where their value lies, in reliability, precision and standardization. However, manufacturing processes that involve a high degree of variance and non-standard steps, performing exactly the same action is a liability for the robot, meaning it can have difficulty performing its tasks. At Danfoss how do we help the robot overcome the challenge of handling and mounting a huge variety of different-shaped components? We apply the science known as Design for Automated Assembly (DfAA). What concrete steps do we take using DfAA?Firstly, we design our manufacturing equipment to assist the robot: we design in mechanical fixtures and sensors to help the robot make decisions. For example, a vision sensor can help the robot pick up components correctly. Secondly, we design our product components and packaging in all kinds of detail, to preempt or compensate for possible variations in tolerance: - We collaborate with our suppliers to ensure components are easy to pluck from well-defined packaging and apply to the kit tray- We avoid sharp edges and instead design in chamfers, so male elements guide themselves into place when connecting with female parts. We use common gripping elements on different components, wherever possible. We put reference guides in place, that gently tap and rotate components into the correct position. All these efforts are examples of self-alignment design. This approach to design is an iterative process and requires ongoing negotiation between the factory and the R&D department. Naturally, we don't want to compromise on design where it might affect product performance. It's a sophisticated balance requiring advanced tools to simulate the consequences of each individual decision.Collaboration between manufacturing and developmentDfAA is a clear example of the close collaboration required between R&D and the factory. This collaboration is illustrated in the hierarchy of criteria of product characteristics, which forms the basis for manufacturing priorities. The hierarchy of criteria includes characteristics which we want our products to exhibit, ranked in level of importance. Characteristics which find their way into the hierarchy WHAT MAKES THE SMART FACTORY A GAME CHANGER?Martin Høgsbjerg
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