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Manufacturing Robots Dos and Don’ts

Manufacturing robots refers to a common practice of automating repetitive, tasks across the manufacturing process. The company objective is to reduce manual errors, increase production task and save costs. There are many manufacturing robots for sale but not all of them suit the automation task you want to achieve.

Which manufacturing task should you automate?

This simple question needs a clear answer, it is important before starting in automation to have a clear objective of which tasks need to be automated.

In summary, the criteria for selecting the right robot automation for any manufacturing applications are:

• Tasks with high error rates in the process
• Dangerous or arduous tasks for workers
• Manufacturing processes with an automatic task but require manual intervention
• Night shift tasks
• Repetitive tasks
• High-quality products
• Tasks that need skill workers
• Manually triggered processes

Dos of robotic automation

Industrial robots are widely used in car manufacturing but they are not only relevant for large enterprises, but SME’s (small and medium enterprises) as well.

Everything we do, need a plan to avoid increasing the cost or rework the project. It is crucial to understand how to start, we intend to provide a guide as robot integrator and also as one of the automation companies in the UK.

Walkthrough of the existing process

Before automating a process, it is important to a walkthrough of the existing process with the responsible manager or people involved in the process. Whether you are large enterprises or SME’s enterprises.

Write a Detailed Process Document

Prepare a detailed process map with all elements that need to be improved, like the following:
• Purpose
• Scope
• Trigger and Output
• System in Scope
• High-Level process in scope
• Detailed process description
• Process Details
• ScreenShots

It is always good to come back to this document after the system is installed or during the installation or robot automation process.

Create a diagrams process map

The detailed process document is useful as a reference and saves a lot of time, but a diagram or process map helps you to visualise the whole process. However, it shows the interaction between process components and emphasize that concept phase of the investment lifecycle and is intended to describe the conceptual design of the proposed system.

This document provides a framework for more detailed requirements and design activities in the later phases of the project. Therefore, if the process is complex and it is necessary to create multiple workflows integrating, the diagram can be reused for each step of the automation.

Search for the right Robot Integrator

There are many system integrators but not all have robot integration experiences. It is essential to request for real cases studies especially cases related to the application the company are planning to perform.

Knowledge of the market is essential, and an integrator must keep updated on new technologies. Therefore, it is ideal to meet with the integrator, they can help the company to understand the steps of the integration and what it is involved.

Don’t of robotic automation

Here are some of the common mistakes that must be avoided during manufacturing robots process.

Selecting the wrong industrial robot

Not all industrial robots are suitable for all robot applications. It is not easy to start the automation, if a manufacturing process is wrongly automated, it might lead to a waste of time and money. It even renders the whole exercise a failure.

Readability Simple script code

It is always the assumption that the developer is the only one who needs to read the code. It is the main reason why the readability of code is often ignored but the developer should not retain the code for a long time. For instance, programming robots in a simple, well structure and understanding code help companies to avoid future issues.

Furthermore, a new developer may not understand the coding of the actual developer. Therefore, using best practices for readability is essential for new and experienced developers.

Rushing into automation

Companies may tend to rush through the design process without finalising the design, exposing to errors, incorrect robot automation or lack of understanding about the whole process which leads to wrong decisions.

It is important to leave scope for future modifications or expansion. Review the scope document carefully and make sure to include a robot integration deadline.

Maintenance and breakdown

Planning for breakdown and future maintenance is often ignored. Keep a proper maintenance program to avoid breakdown.

The goal here is to test each component after the automation, provide proper robotic training to the staff to reduce the breakdown due to lack of knowledge. However, to ensure the manufacturing robot team stays in sync with automated systems, consider periodic demos of the performance of the whole process.

How much do manufacturing robots cost?

Manufacturing robots cost vary according to the task that the robot will perform, the payload and the automated equipment included on the system. Please check out our Robot Automation System ROI Calculator to get an idea of the cost. Likewise, it is essential to contact a system integration company that can help reduce the cost of the project.

Phoenix intend to provide a do and don’ts guidance for manufacturing robots but it is important to consult a robot integrator to customize you entirely project based on your needs. Contact Us for free consultation or check out robot applications: milling robots, welding robots, and more.

November 15, 2019November 16, 2019Robotic Automationmanufacturing robots, Robotic ROILeave a comment

Robotics in Manufacturing

Manufacturers remain reluctant to implement robotic in their production process but a majority of those surveyed found robotics in manufacturing will improve productivity and safety. However, one of the big challenges is the shortage of skilled workers in manufacturing.

Other missing factors are the lack of leadership or management skills and automation knowledge. In spite of challenges, still confidence in manufacturing to fill the gap with their own workforce based on-the-job experience.

2018 Salary Survey: Skilled worker shortage, challenges

It is true that industrial robots are helping manufacturers because project manager supervises less employees, but it will not solve all management skill problems. In fact, there is a lack of robotic automation skills for a successful of the automation project.

According to 2018 Plant Engineering Salary Survey , finding more workers is the singular issue facing the industry. Finding leaders from among the current workforce is a less visible issue, but it will become a greater concern as the older workers move closer to retirement.

Get peace-of-mind with Robot Automation

All plants have some form of robotics in their facilities, robots offer peace-of-mind because they produce high-quality work. Therefore, improving productivity.

They can also be predictable allowing employees to focus on other tasks. In fact, training and keeping the operators are more expensive than maintenance and the programming of the robots.

One more factor to consider is that they can be reprogrammed to perform a other applications and refurbished to extend their useful life by providing proper maintenance.

On the following chart, we can see the main benefits of robotics in manufacturing. In this survey productivity is the highest robotic value for manufacturing.

Robot Integrator companies provide training to the operators and we are helping employees to start in automation.

Phoenix offers a complete package of robot automation system for any robot applications from a single robot cell design to an assembly production line including control panel, electrical panel wiring, electrical panel design.

September 23, 2019September 23, 2019Robotic AutomationLeave a comment

Control system Integration challenges

Five Industrial Automation Challenge

Tips to manage and execute them with success

Control System integration technologies are changing rapidly, and manufacturing automation projects are becoming a challenge due to the complexity, scope and human intervention.

Manufacturers need to cope and carry on with the constant changing in the way manufacturing process technologies is moving forward. Therefore, as an integrator, we can identify five manufacturing automation challenge:

Tips No. 1

Control System Components:

When building a control system need to consider several components from different suppliers. Furthermore, the project manager must ensure that all these components can communicate with each other without any setback. Industrial engineering knowledge is crucial to deliver a top-performing integrated system.

The operator interface (OI) is one main component for automation system. For instance, it is essential for the operator understand interface between all automated equipment in a plant to achieve the operation successfully. In addition, a system integrator can help the operator to get an accurate understanding of the whole operation system. Hence, it is important to update the interfere need according to the latest technology, it is crucial to get the operator embrace the changes by incorporating the latest technology.

Tips No. 2

Technology Interfaces:

New technology represent a challenge for any automation project. However, updating the equipment with the constant changing of the software is a challenge, electronic technology or others automation equipment can make the different in implementing a functional and high-performance control system integration or a poor performance system. Likewise, it is important to train the staff with the latest automation technology to keep the system running smoothly.

Tips No. 3

Control and Field Instrumentation Documentation:

Engineering expertise must follow documentation standards. In Fact, to successfully work with and well-structured design control systems, it is essential to understand the documents that are typically used to illustrate process control.

System integrator provides a very detail documentation that include all requirements from the automation control system. In short, the documentation of the control system does not follow standards that for process control and instrumentation, then it may be necessary to manually create this documentation. For example: tag numbers may easily identify the field device when ordering and shipping, as well as installing in the plant.

Tips No. 4

Process Flow Diagrams:

The project manager is responsible for the selection of the devices that best matches the process design requirements. This includes the selection of the transmitters that fit the operating conditions, the type and sizing of valves, and other implementation detail specified in the process flow diagram. Some of these diagrams are:

Piping and Instrumentation Diagram – On the diagram describes all decisions or changes concerning field instrumentation, the assignment of device tags, and piping details. (P&ID)
Loop Diagram – Drawing that shows field device installation details including wiring and the junction box (if one is used) that connects the field device to the control system.

Tips No. 5

Future Expansion:

Companies need to plan when develop a complex or even simple automation control system projects before jumping into execution. Searching for the right system integrator team early in the process and designing appropriate engineering design is key.

Performing an appropriate scope is critical to getting the project started and for future expansion. Consider company growing when implementing a control system including control panel expansion, industrial electrical wiring and software upgrading capabilities.

Maximise the ROI

Industrial automation projects have so many challenges, find a right partner with enough knowledge and extensive technological expertise to integrate the automation system and its components. For instance, searching the right control system integrator can help guide the project to success and maximise the ROI from an automation project.

Phoenix installs and integrates industrial control panels. We can customise a single or multiples control panels as well as provide the electrical wiring design and documentation. In addition, we offer our project management and commissioning solutions.

August 29, 2019August 29, 2019Industrial automation systemsLeave a comment

Can Robot milling replace a traditional CNC machine?

Robot milling involves adding the flexibility to replace a traditional CNC machine

Robot milling can now replace a machine tool in certain applications, bringing a high level of flexibility to use different tools in the 3D space. Robots are capable of producing the highest quality complex and unusual geometries parts. Automated milling systems can have flexible tooling for specific material removal.

Robot Milling can process a variety of different materials from alloys to plastics and from foams to timber. A robot is capable of milling any object of any size or shape by just adjusting the robot programming and end-of-arm-tooling.

We can find Industrial robots in a great variety of applications such as handling, welding, assembling and robot milling operations. Especially for machining operations, industrial robots represent a cost-saving and flexible alternative compared to standard machine tools. With the knowledge of interaction along the milling path, a general model-based path correction strategy is presented to significantly improve accuracy in milling operations.

Why working with a industrial robots?

Automotive Industry is using Robotics, where the robot usually execute a single routine following a set of 3d-Curves (circular or linear interpolations or PTP (Point to Point) movements). You just need to program the robot once to do the same operation for the whole lifecycle.

Milling Automation is a fairly new application for robots and not widely used. Programming is still a big challenge because the robot’s programming software does not support automatically programming of multiple tasks and spline-geometry.

With using CAM software, we have the advantage that we can use the CAM-strategy of contour milling, the end mill can follow the splines according to the surface normal.

Robotic milling is advantageous in several aspects:

Increase Flexibility – Robotic milling greatly increases the flexibility of milling.
Lower Cost – Robotic milling can be cheaper than CNC.
Through the flexibility in workspace the robot supports undercuts and can work from all directions.
A further advantage is the (non-cubic) workspace. In contrary to portal milling machines, a robot does not operate within a fixed frame.
Calibration and self-reference of the robot: the robot can reference its own position to the model.
Industrial robots can work in diverse are as 3-D-printing as well as for milling or drafting.

CAD-CAM Solutions

Phoenix Control Systems will guide through the robot automation and complete the project. We will design, implement and test the complete systems.

Check also Welding Robotic, Assembly robots, Palletising robots and Welding tomorrow

August 14, 2019August 14, 2019Industrial Robot, Robot Application, Robotic Milling, RoboticsRobot MillingLeave a comment

Industrial Automation New Technology

Mobile Technology is moving into Industrial Automation

In recent years industrial automation new technology such as the mobile devices are playing an important role in every aspect of our lives and they are increasingly demanding with automation systems changing how data is analysed, stored and acquired.

Hence, some larger industrial control companies already have integrated mobile with data acquisition application to their automation products. In addition, they are integrating mobile communications systems for better performance.

Mobile capabilities for Automation Systems

Hardware and software are part of the operations technologies in manufacturing plants, while information technology is for mobile communication systems. For instance, by integrating these two technologies, the end users engage their mobile devices with no restrictions. It requires to install specific software and more advanced programming or configuration. Therefore, using a familiar web browser gives users the capability to do some setup in mobiles or tables devices. Eventhough, PC access nor internet is required to do the work. Why to invest in robot technology ? See the main advantages of this new technology.

10 Top Advantages of Mobile Technology for Industrial Automation

Traditional Industrial Automation include more complex architectures or steps while mobile technology provides simplified solutions. Also, see some of the advantages of the newer technology:

1. Improves data flow
2. Control who can have access to the data
3. Data provides additional services to customers and improve machine design.
4. Operators can monitor equipment located remotely or in hazardous areas
5. Progressive original equipment manufacturers (OEMs) will build the right data points into their equipment and gather results from a machine, a site, or even multiple sites
6. Management team and OEMs can access information from industrial automation systems from their Mobile
7. Remotely assess operating conditions
8. Reduce energy consumption and maintenance costs, and to improve efficiency
9. Access to more detail data; when and where owners of staffs need it
10. Preventive or predictive maintenance via details analysis

Mobile Security Concern

Even though the adding of mobile devices have advantages, it can also raise concerns about who can see or change industrial controller data. For instance, in a traditional systems a serial cable connect the the hardwired interface terminal to a PLC, the HMI user experience is local and separated from the rest of the world.

Security is also of great concern because it demands more attention for a mobile device on Wi-Fi network, or connecting over the internet. In other words, it means all efforts shoudl focus on the security over external jackers.

Robot Automation Systems

The mobile devices and applications are now advancing into the industrial robot automation systems because robot system is integrated to the plant operation process. Industrial robot – new robot or used industrial robots – are part of whole process and they can also be monitored on how data is acquired, viewed, stored, analysed and acted upon.

Therefore, factories can include any application such as robot milling, robot palletising, robot cutting, trimming, Robot robotic welding, or painting robot as part of their industrial automation.
Whereas factories want to include control systems, robot automation or mobile technology into your automation systems, it is crucial to consult with a Control System Integrator, Robot Integrator or both depends of the complex of the project.

Nevertheless, Industrial integrators will advise and guide you throughout the whole process saving time and cost.

See other Robot 3D Printing Technology

July 1, 2019Robotic AutomationLeave a comment

Most frequent mistakes made by control panel manufacturers

Control Panel manufacture can build panels, but few can build a long lasting high-quality industrial control panel. However, control panels are not just one more item for the project. For instance, a quality control panel manufacturers are important to production and to maintain the project lifecycle.

Above all, the system integration project managers should have a detailed list of the necessary equipment they will need for a project to allow panel builders enough time to work on the input/output (I/O) of the control panel. Also, it is possible that they may need to do some change as the project progresses. In addition, a system integrator must take the time to ensure the quality and efficiency of the control panel.

In other words, a system integrator will have engineering services along with a panel manufacture plant that centred on design and the building of the panels in order to avoid the most frequent mistakes made by the control panel builders. First of all, see below a detail list of the most frequent mistakes.

Some of the Most frequent mistake made by manufacture

1. Lack of quality control.
2. Components are not labelled or are mislabelled.
3. Loose wires.
4. Not enough room for wiring.
5. Panel not tested.
6. The drawings may not match.
7. Wires not properly terminated.
8. Lack of or badly done thermal calculations for the panel

Types of Control Panel Systems

Every industry will require a specific control panel for the operation of the business. Therefore, there are many types of industrial control panels for all kind of industries such as Pharmaceutical industry, Automotive Industry, Packaging & Machinery, Petrol Pump, Heating Systems, compressors, Security & CCTV Equipment, Nuclear power stations, Belt Control Systems, Access Control Equipment and industrial equipment.

However, a reliable control system integrator would know exactly what to do in every case. All components of the indutrial control systems such as electrical design, electrical panel wiring, the PLC programming or others elements of the panels itself should be the best quality products on the market and well-known brands.

Phoenix builds control panel for high demands sectors. Therefore, we design and install from single or multiple panel build systems, through to full custom integrated systems. We can also modify existing control panels or remove and replace existing panel to add a new design to be fed from the panel. For instance, we provide the Project Management and Progamming PLC & HMI.

Moreover, it is crucial to find a that follow all regulations.

See more Industrial Control System

May 15, 2019May 28, 2019Industrial control systemsLeave a comment

Industrial Automation Systems How to Stay Competitive

Industrial automation systems offer a variety of automation solutions to help manufacturer. Some industrial automation are more complex than others, for this reason, it is imperative to find an industrial automation companies with experience on this subject.

Starting with automation may be high initial cost but the advantages are worthless, for example some of the most well-known benefits include faster production and cheaper labour costs. Also, automation will carry on with a minimum human intervention while reduce operation time and improved product quality by consistency on the process.

Automation use various Industrial Control Systems to perform the operation of a specific process in factories. Even though, not all process can be automated, it will help manufacturers to stay competitive.

Top elements by using Industrial Control Systems

An important part of Industrial Control Systems include a programmable logic controller(PLC). PLCs are used to synchronize the flow of inputs and outputs and Human-machine interfaces (HMI) will communicate with PLCs and other computers to display any event on the screen. Hence, the operator will monitor the entirely process.

Some most frequent terms related to the industrial automation system include Control Panels, Electrical Control wiring and programming. Therefore, it is important that the system integrator company provides a detail document to help the customers for future expansion.

Industrial Robot Automation

Industrial robot arm are also part of the industrial automation process. Therefore, industrial robots help companies in manufacturing process or harsh environments for human. They are extremely accurate machines.

There are many industrial robot applications from simple robotic welding systems with one single robot arm to more complex procedures in a production line factory which involves several industrial robots or other machines interface.

Why a Robot Integrato?r

A robot integrator will design a robot system according to your needs including robot cell design, robot training or industrial robot programming. They will do the full robotic systems integration using new robot or used industrial robots.

The concepts of the Industrial automation systems are changing is not just industrial control systems or robotic automation systems, but also the new introduction of the digital transformation or Internet of Things (IOT). It means, the main goal of companies is not only automating operation process, but also fully automating the data.

Digital Tranformation or Internet of Things

While the vast majority of respondents, more than 80%, say their organizations see digital technology as an opportunity, only 26% say their companies see it as a risk. The fact is what is good for one company can be just as good for another — competitors may be able to quickly catch up, see more Detoitte Report.

Whatever the end state of digital transformation turns out to be, reaching it is not simply about technology. Digital transformation is the product of strategy, culture and leadership. Digital transformation is about strategy, networking, culture changes, and process analysis.

Industrial Automation Trends

Understanding the existing Industrial automation trends would guide companies to take the best partner to implement the transformation and which of them are the most reliable and experienced.

Phoenix would keep our customers updated with the latesst news related to Industrial Automation in the UK. Our customers sucess is our success.

May 14, 2019May 28, 2019Industrial control systems, Robotic AutomationLeave a comment

The future of Robotic Automation Systems

THE NEW FUTURE FOR ROBOTIC AUTOMATION SYSTEMS STARTED

The future of robotic automation systems is here with new technologies. It could be the start of a new era of working with robots cooking, robot serving food, robot surgery or what about robot in the construction, lawyers, architecture design? Who knows what else we will hear about working with robot in the near future!

As well as the many automotive applications, robots are now found in a variety of other industries with this wider use, there has been a significant increase in the number of people or industries that need to work with robots including the process designers, control engineers, architects to mention some of them.

Restaurant’s Robotics Technologies

Manufacturers of new robots are busy launching new products in the past year and, although the take-up still varies between market sectors as automotive, plastic/rubber and food/beverage are the largest users, but new industries are emerging. Some restaurant has taken a huge step into the future investing in new robotics technologies Yes, you can finally say that you can be served by a robot!

Medicine is using industrial robots

Scientists in the US have developed an autonomous surgical robot designed specifically to suture – or stitch up – soft tissue. And in testing, this surgical machine – which, it will operate entirely independently of human control. The results, reported in Science Translational Medicine, compare things such as the quality of the suturing, along with the amount of time the surgery took, and the number of mistakes made.

Robot Servicing

Lawyers can get the information with an “artificial-intelligence attorney”. Its capabilities of learning allow it to continue improving its answers and also help keep lawyers up-to-date about new rulings and by reading carefully through every single case it provides quickly the information that might be relevant to the cases. We may probably see them in the courtroom anytime soon.

Robot Integrator

We will find the robotic automation systems not only in robot milling, robotic material handling or robotic welding systems but also in many others unthinkable areas. Phoenix Robotic will keep you updated with the new technologies nowadays simply visit our website www.phoenixrobotic.com and Contact Us.

Check Out this article

April 9, 2019May 15, 2019Industrial Robot, Robotic Automation, RoboticsLeave a comment

HMRC letter provides the latest guidance to businesses about the UK leaving the EU

Industrial Automation in UK are leading and helping UK economy, therefore they play an important role when talk about UK Leading the EU. HMRC keeps industry informed about steps to follow on the near future.

HMRC have published HMRC latest letter to UK businesses that trade only with the EU, with details of important actions they need to take and changes to be aware of in the event of the UK leaving the EU without a deal. It is our third letter to businesses on preparing for the leaving.

The letter asks businesses to take a number of actions to prepare for no deal. These include:

registering for a EORI number at Get a UK EORI number to trade within the EU

deciding if they want to hire an agent to make import and/or export declarations for them or if they want to make declarations themselves using relevant software

registering for Transitional Simplified Procedures (TSP), which is a new process to make importing easier than it otherwise would be for the initial period after the UK leaves the EU, should there be no deal – registration opens from 7 February on GOV.UK.

There are also important updates on the way businesses trading with the EU pay import VAT and use EU VAT IT systems if we leave with no deal. You can read the full letter at Letters on ‘no deal’ Brexit advice for businesses only trading with the EU.

These changes do not apply to trade across the Northern Ireland-Ireland land border. We will set out information about the arrangements for trading with Ireland as soon as we can.

New Guidance

HMRC have also published new guides on GOV‌.UK

Customs procedures

Moving goods to and from the UK

VAT IT systems rules and processes

The guides provide further information explaining what these changes mean for all companies including the industrial automation in the UK that trade with the EU. You can find the guides at Trading with the EU if the UK leaves without a deal.

New ‘Prepare your business for the UK leaving the EU’ tool

HMRC have also published a this tool to help UK businesses find out:

what they need to do to prepare for this event

what’s changing in their industry

information on specific rules and regulations

All businesses need to do is answer 7 simple questions to get guidance relevant to them and their sector.

System Integrator

Phoenix, Industrial automation companies in the UK, is very pleased to contribute with this important news. A reliable system integrator must keep informed about all news related to the market. See also The Future of Robotics.

By Deputy CEO and Second Permanent Secretary –

February 5, 2019May 14, 2019Industrial automation systemsLeave a comment

“TOP 5 REASONS” Why Robot Systems can benefit your business?

Robotic Automation as the Collaborative robots are a hot topic in manufacturing today. Some of these new robots are Universal Robots, Rethink Robotics, KUKA and ABB. They are hitting the marketplace and bringing robotics to small shops and factories.

The robot industry itself generates 170,000 to 190,000 jobs worldwide, including the support staff and operators, another similar number of people. There are three other types of robot application where robot systems create or preserve jobs. When can robots do the job?

When the product require satisfactory precision, consistency and cost.
Where the current work conditions are unsatisfactory, but where a robot will operate.
Where a high labour costs is threatened by a unit in a low labour cost area.

Phoenix provides the time, talents, technology to optimize your robotic automation process. Ou robotic systems integration experience will ensure the best robotics solution four business.

The automation of the fourth industrial revolution is accelerating: By 2018, around 1.3 million industrial robots will be entering service in factories around the world according to the survey from IFR .

Robot service is the next generation that will be used in industry, but some may probably become “Consumer products”. Therefore, this implies major new manufacturing activity. As quantities will be large, and precision and consistency are critical, this new manufacturing is going to need robotics. Alongside this is the employment of a whole new workforce.

What the experts in Robot Systems says?

“Today there are more opportunities than ever before in the robot industry,” said Jeff Burnstein, President of RIA. “The continuing growth in robotics is opening many new job opportunities for people who can program, install, run, and maintain robots. In fact, if you look closer at the jobs discussion, robotic automation is helping to save and create jobs.

“The robotic boom is laying down an important milestone in the realisation of the fourth industrial revolution”, says Joe Gemma, President of the International Federation of Robotics… Further impetus is coming into the form of the technological breakthrough in human-robot collaboration: Robotics workers will in future be found working hand-in-hand with human staff, helping to replace traditional, rigid production processes with flexible structures.”

May 9, 2017December 3, 2018Industrial Robot, Robotic Systems, RoboticsNew robots integration, Used Robots integrationLeave a comment

Robotic Integration

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