In order to be on track with today’s fast-paced, technology-driven world, industries have begun integrating automated processes to their production floors for a more efficient way of manufacturing goods. Robotic installations are a prime example of a crucial technology needed in present-day manufacturing. When performed correctly, robotic integration has many benefits. However, there are precautions that must be taken in order to ensure the technologies are installed swiftly and correctly. Often, robotic integrators are forced to shutdown equipment, or entire production floors in order to achieve this. This is referred to as Factory Shutdowns.

What is a Factory Shutdown?

As the name implies, a Factory Shutdown is a temporary closure of a production building to perform maintenance. Usually, these shutdowns are done to perform equipment inspections or deal with unplanned downtime. They are also performed to allow the integration of new equipment or technologies. Time, effort, and money devoted to shutdowns can sometimes be underestimated. This is due to the fact that elaborate planning and executions are required. Integrators may be unaware of certain layouts on a machine floor and will need equipment to be relocated to install their technologies properly. Or perhaps a software component within the machines (new and old) must be compatible in order to operate as one. Processes such as these are lengthy and costly, the company or the integrator must ensure every aspect of the integration process is planned and executed correctly to not waste possible production time, and in turn, reduce profits.

How DIY Robotic Cells can Help

How to Avoid or Reduce Shutdowns

Due to the nature of shutdowns and how they reduce profitability, companies should try to reduce the time spent in shutdown, or eliminate them entirely. Below are a few solutions to optimizing factory shutdowns due to robotic installations:

  • Develop a strategy in advance on how to accomplish integration. This includes assigning job tasks, resource planning (people, materials, tools), risk and safety assessments. This ensures that if any aspect of the integration process is delayed, there is a concrete plan set in place to put it back on track.
  • Schedule enough time in the case that issues arise. No matter how detailed a project plan is, unplanned work is inevitable. Not accounting for this work can have a huge impact on a budget or timeline. A time threshold should be set in place to ensure unseen issues do not ruin a project.
  • Employ an integrator with a time-efficient process to installation. This could involve prebuilding equipment that can be installed with ease, rather than supplying a company with only the parts.
  • Employ an integrator that offers a turnkey solution. Since all phases of integration are consolidated under one company, tasks are easier to plan, communication errors are less likely to occur, and any errors in integration are left to the experts. This will save a tremendous amount of time, for both parties.
  • If there are multiple production devices available, integration of the new technologies could take place on one of the devices while the others are still operating. This ensures the product is still being created while upgrading the upgrade is taking place. If there is an error with integration, only one machine would be affected.

How DIY Robotic Cells can Help

Factory shutdowns are a lengthy process. Companies should find a robotic integrator that can install technologies effectively, while still optimizing installation time. DIY Robotics provides the necessary solution to optimizing shutdown time. All DIY Robotics products come pre-built which reduces installation time greatly. Our cells are also modulare, which means they can be moved or altered with ease. Many robotic installations are bolted to the ground and therefore are fixed in position. These robots take unnecessary time to install or maintain (adjustments). By choosing DIY Robotics products, installation or maintenance can be easily executed due to its modulare capability. DIY Robotics also offers its products in turnkey solutions through a panel of official integrators familiar with the product. Integration/Customization of our machines can also be made at our facilities. All unexpected errors would be addressed before delivery, and any unique customizations would also be established. This could involve certain cell layouts, adjustments on the robot, custom EOATs, etc. Therefore, it would only take a few days to make a production line operational.

What is a Factory Shutdown?

All of these benefits listed above can help reduce shutdown time tremendously. A shutdown timespan of 2-4 weeks could easily be reduced down to 2-4 days with our products. If you are interested in learning more about our robotic cells, or have a question regarding other technical material, please feel free to visit our products page or contact us.

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