Integrating sensing, vision and robotics, this example of an advanced production line control solution enhances the performance of both humans and robots as they learn from one another. Accelerated employee training and knowledge transfer, zero defect production and enhanced workflow efficiency are just three of the direct benefits that many manufacturers, including high-mix, low-volume (HMLV) operations, will glean from implementing this new line control approach.
The brand-new production line control platform has been tested and deployed at OMRON’s flagship manufacturing factories in Japan and China with impressive results; at the Kusatsu factory in Japan, assembly time was reduced by half and productivity improved by at least 25% up to 200% in high-mix and variable production.
Antonio Farras, General Manager at the OMRON Automation Centre in Europe, explains the thinking behind the new line control concept: “Skilled worker shortages, social distancing measures and economic pressures are making it increasingly difficult to improve productivity and maintain quality when focusing on high mix, low-volume manufacturing. In this context, technological innovations such as AI and IoT offer huge potential for solving some of the problems faced by companies operating in this industry.”
Antonio continues: “We have harnessed these technologies to visualise a new manufacturing environment that combines the strengths of humans and robots. Employees can be trained in almost no time and real time work checks, through sensors and automated visual tools, rapidly improve their skills while guaranteeing product quality. We believe this control solution has the potential to transform the performance of production and assembly lines the world over in terms of quality control, training and productivity.”
OMRON’s Intelligent Cell Production Line concept uses smart sensing and integrated control to enable dynamic optimisation of assembly lines. In an HMLV production scenario, the line is an innovative control and information system supporting efficient and high-quality production where high-mix and variable-volume manufacturing is required.
During each step of the production or assembly process, sensors and automated visual tools ensure consistent product quality. Any mistakes or skipped processes are detected in real time, maintaining the pace of assembly. Cobots check the quality of the assembly and correct errors for zero defect production. This also provides support, correction and training that improves the skills of employees without the need for intervention from human line managers.
OMRON’s Intelligent Cell Production Line can also enhance materials handing efficiency; intra-logistics can be improved through the use of autonomous robots that are capable of feeding production lines with just-in-time materials and many more benefits including:
- Work-in-progress inventory can be reduced and mistakes prevented through the optimal use of Mobile Manipulator (MoMa).
- Identifying the worker and order type for optimised machine adaption
- Coaching for multi product orders in small batches
- Traceability: Monitor quality fluctuation and control feedback to production line with link to production and inspection information. Tracking and tracing for sustainability and serialisation
