How does C&C Marshall keep its competitive advantage?
Installing Toshiba Machine's SR-554 HSP provided payback in just six months.
More and more companies are turning to robotics to reduce operating costs. One such company is cable management specialist, C&C Marshall Ltd. The company has installed two Toshiba Machine SR-554 HSP SCARA robots at one of its UK plastics molding plants. The installation was prompted by the need to reduce the man-hours spent on the shop floor and increase production. Before the investment in robotics was made, the now automated functions were performed manually. However, this was inefficient and generated problems of its own, including repetitive strain injury.
"Often manufacturers who have never worked with robotics, discover unexpected benefits when they do," said Nigel Smith, Managing director of TM Robotics. "Avoiding costly compensation claims for RSI is one of these. The more tangible benefits are production increases and the ability to function on a genuine 24/7 basis."
Toshiba Machine SR-554HSP robots were selected over five-axis systems because they offer greater speed, improved accuracy and far more attractive prices. In one application the SCARA robots work in conjunction with a plastics moulding machine and a Cartesian robot. The SCARA positions swivel clamps in dry lining boxes, for use in electrical installations. When installed, the box sits between the socket plate and the wall. It contains the switchgear needed to operate the socket, keeping the system insulated.
The process uses the Cartesian robot to move four dry lining boxes from the moulding machine into inserting nests, where the swivel clamp is inserted. The Toshiba Machine robot is bowl-fed with the clamps and places each one in the correct position in those mouldings or boxes. The Cartesian robot then pick ups the boxes and drops them onto a carrier before they are placed onto a packing carousal.
The gap, into which the clamps are inserted, is less than 5mm wide. The repeatability of the Toshiba Machine SCARA is therefore vital. When choosing such a robot the distinction between accuracy and repeatability is of major importance. Accuracy applies to just one movement. Repeatability ensures the accurate movement is repeated on every occasion.
Operating on its most common program, the system shifts 10,000 dry lining boxes a day. Before automation, the clamps were manually inserted into the boxes. Just three people now operate the entire SCARA system. Previously eight people were required. Given that five to six tons of boxes are produced per week, this represents a significant improvement on the factory's bottom line.
"The typical payback on a SCARA is eighteen months, but this system paid for itself in six. Obviously, the smaller the manufacturing run, the longer the payback time, " said Nigel Smith, Managing director of TM Robotics. "The reluctance with employing automation lies not with the plant engineers, but in the boardroom," said Smith. "Financial directors often know little of engineering.
Thus, it is understandable that these people might believe that an extra injection-moulding machine might be the best way of improving productivity. However, as we have demonstrated, this isn't always true. An improved process can be even more valuable."
Case Study originally published on Thu 23 Aug 07 13:34