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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
Reception General. IT-infrastructure Accounting & Finance Reporting
Bending Alu-profileswww.bestbend.com
Subcontractor Mechanical partswww.aluro-cnc.com
Equipment insulating profileswww.aluro.com
Aluro-Group companies
Easily automate your CNCwww.robojob.be
9/05/2011 2Helmut De Roovere
9/05/2011 3Helmut De Roovere
Competition on international level
Prices dictated by a global market
Benefits & Handicaps when producing in Belgium
….
Our customers work in International markets
9/05/2011 4Helmut De Roovere
Small variations by the end consumers lead to amplified variations every step downwards the supply chain
Industry 2011 = Supply chain
Production companies must be SUPER flexible, smaller lotsizes, rapid manufacturing of prototypes, shorter lead times, ….
9/05/2011 5Helmut De Roovere
Internal capacity mechanical parts
Market demand
Time
Overtime, weekendwork, work during vacation, recruitment, (over-)
investments,…STRESS
Tempory unemployment,dismissals, insolvency,…STRESS
Recources
24h x 360 days = 8640 h
14h x 220 days = 3080 h
Machine capacity
Operator capacity
9/05/2011 6Helmut De Roovere
a glimp at our labour market
Evolution of labour cost in Industry
Gross added value per person Productivity upcoming economies
9/05/2011 7Helmut De Roovere
Schrink of our working population
Evolution of Gross margin
1995
Market tariff CNC work 60,- €/h
Labour cost CNC operator -22,- €/h
Depreciation of CNC machine -12,- €/h
Tooling cost -5,- €/h
Gross margin 21,- €/h
2010
60,- €/h
-38,- €/h
-12,- €/h
-5,- €/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 8Helmut De Roovere
Summary of analyse
9/05/2011Helmut De Roovere9
+ 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
Our goal at RoboJob
9/05/2011Helmut De Roovere10
2010
Market tariff CNC work 60,- €/h
Labour cost CNC operator -38,- €/h
Depreciation of CNC machine -12,- €/h
Tooling cost -5,- €/h
Gross margin 5,- €/h
30% is set-up related
70% is related to production output
Small & medium lot-sizes
We aim to cut this labour factor
9/05/2011 11Helmut De Roovere
Integrated Robot System-Chuck Work
What we developed …
9/05/2011Helmut De Roovere12
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
Results within normal working hourswhen making small & medium batches
1995
Market tariff CNC 60,- €/h
Labour cost operator 22,- €/h
Depreciation of CNC 12,- €/h
Tooling cost 5,- €/h
Gross margin 21,- €/h
2010
60,- €/h
38,- €/h
12,- €/h
5,- €/h
5,- €/h
2011 + RoboJob
60,- €/h
13,- €/h Only for Set-up
12+6=18,- €/h Additional depreciation
5,- €/h
24,- €/h Back in business !!
9/05/2011 13Helmut De Roovere
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
9/05/2011Helmut De Roovere14
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) !!!!
0 €
20,000 €
40,000 €
60,000 €
80,000 €
100,000 €
120,000 €
140,000 €
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Possible additional gross margin
9/05/2011Helmut De Roovere15
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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9/05/2011Helmut De Roovere17