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When looking to invest in a high-value piece of automation equipment, a key question of any potential purchaser is: what is the payback period? In the UK, the typical expectation is that this will be under two years. Yet the value that the right automation solution can deliver to a manufacturing business will last far longer than that. This focus on short-term return is hindering our productivity as a nation. Our neighbours in the EU typically expect payback in three to five years, which goes some way towards accounting for their higher levels of both automation and productivity (a German worker produces around one-sixth more per hour than their UK counterpart[1]).

Despite our relative reluctance to automate, the UK recently overtook France to become the eighth largest manufacturing nation. If we are to continue competing on the global stage, however, then it is imperative that we increase our level of industrial automation – we currently languish in 25^th position in the IFR global robot league table – not least because of the ongoing labour shortages across all areas of manufacturing. We are the only G7 nation to sit outside the top 10 robot adopters; that alone should inspire us to increase our levels of automation in order to drive higher productivity, greater efficiency and increased output.

To do that, we need to get realistic about return on investment. Focusing on a sub-two year payback can lead to businesses making compromises when developing their manufacturing strategy, and thereafter their capital equipment and automation purchasing strategy, and forces decisions to be made that do not offer long-term value.

By contrast, determining the value of automation using total cost of ownership (TCO) is a far more accurate measure. Any investment in capital or automation equipment should form part of a business’ long-term strategy, and not simply because the purchase price fits into an arbitrary short-term payback period. By calculating the lifetime costs – and more importantly, the lifetime savings – associated with automation, manufacturers can ensure that the sums add up in the long term and not just at the point of purchase, resulting in the right solution for their business both now and in the future.

Below are the nine factors that make up TCO lifetime costs. Before considering any automation purchase, make sure to talk to your supplier about how their solution can help to control these costs, to ensure you’re getting real value from your investment…

1. Purchase price – While much of the focus of any negotiation is concerned with purchase price, it actually only accounts for between 15-25% of the total cost of ownership. Solely focusing on this as the deal-breaker can lead manufacturers to invest in an automation solution which may not be fit for purpose. While FANUC strives to make our products extremely cost competitive when it comes to the initial purchase price, with as much as 85% of the ‘hidden’ costs of ownership coming via other factors, it is counter intuitive for manufacturers to base their sole automation investment decision on this point.

• Training – Whether your workforce is used to dealing with smart, connected automated solutions or is unfamiliar with modern robotics, some element of training will be required to ensure the full value of your equipment can be realised. We offer an array of upskilling resources from our dedicated training facility in Coventry, from basic operating courses to full programming and maintenance courses. Ensure your business can keep up with the pace of change in today’s digital world by making sure any automation supplier you choose offers full training for the lifetime of your purchase.

It’s also important to focus on multiple stakeholder levels in the business. When adopting automation, different stakeholders will require different levels of understanding. For example, at shop floor level a technical level of comprehension will be needed; meanwhile, the C-Suite will need to understand the business case for automation.

• Maintenance – Keeping your equipment running at optimal levels will ensure it delivers day after day, week after week, year after year. Our products are extremely reliable, so much of what we offer from a servicing perspective falls under preventative maintenance. We work with our customers to schedule any required maintenance at a time that’s least disruptive to their business, maximising equipment uptime.

• Repair – The longer a machine is out of action, the greater the financial impact on your business. Speak to your supplier to find out what their average engineer response times are. At FANUC UK, we’re currently sitting at a sub-20 hour mean time to repair any faults, i.e., less than one business day.

• Downtime – Preventing downtime to minimise production losses is essential. As well as ensuring your automation supplier offers preventative maintenance and short repair times, the best way to keep downtime to a minimum is to invest in equipment which has a reputation for reliability. Ask your automation supplier for evidence of its products’ mean time between failure (MTBF). For example, the MTBF for our CNC range is 25 years, and for our robots it’s even longer, at 32 years. Make sure you also find out from your automation supplier what services are available to support reduced downtime occurrences, such as augmented reality 24-hour support helplines. 

• Upgrades – With technology evolving at a rapid rate, your automation supplier should be able to equip your purchase with the latest smart software upgrades as they are released. At FANUC, these include our Zero Downtime (ZDT) programme, which tracks our machines when operational and feeds back performance data to ourselves and the customer. This helps to predict potential issues ahead of time, keeping downtime to a minimum.

• Security – Hand in hand with technological advancements comes cybersecurity. Ensuring that your equipment, as well the data it handles and produces, are kept secure is a pre-requisite and something that we take extremely seriously. Make sure your automation supplier can clearly explain their cybersecurity measures to help your business avoid a costly cyber breach.

• Energy – No longer a ‘nice to have’, sustainability is now a business imperative from a financial, environmental, social and governance (ESG), and legislative perspective; not to mention essential for winning and retaining key contracts. As well as questioning the energy efficiency of any automation solution in terms of the electricity and gas it consumes, make sure to also find out its credentials regarding water usage, particularly when it comes to keeping the equipment clean. However, some solutions go even further and actually re-use energy within the process. For example, our all-electric ROBSHOT injection moulding machine has an advanced power regeneration feature that enables intelligent energy recovery, meaning it consumes 10-15% less energy than other all-electric machines.

• End of life – Everything has a cost to recycle, so you’ll also need to factor in a plan for when your product reaches the end of its life. Of course, this will be determined by its expected lifespan. Will you need to recycle it and purchase a replacement in five years’ time or in 10, 15 or 20 years’ time? At FANUC, our philosophy is to offer the lowest total cost of ownership for our products with extended lifetime service. This means we commit to supporting our products for as long as the customer wishes to use them. We’re still supporting robots and machines that are over 30 years old.

To conclude, if UK manufacturing is to retain its place as a global powerhouse, we must increase our levels of automation. This requires a shift in focus by all stakeholders within a business towards purchasing the right equipment first time around and looking at the overall value it can deliver. Prioritising TCO – rather than obsessing over a short payback period – will help to ensure long-term success, supporting a business’ growth strategy to deliver higher productivity and ultimately, higher profitability.

By Oliver Selby, Head of Sales, FANUC UK

Macadamias are famously the world’s toughest nut to crack. Requiring an extraordinary 300 pounds per square inch of pressure, it is unusual to buy these tough nuts without their shells. Happy Nut by Freedom Fresh Australia is among the exceptions. The Australia-based processing company supplies premium macadamias with a bespoke ‘key’ to crack the nut.

Here’s how the business used robotics from Shibaura Machine to automate the picking-and-placing of keys into their macadamia nut packaging. 

Freedom Fresh has long supplied its Happy Nut brand with a specially designed metal key. The macadamia nuts are cleverly roasted with a slit sawed into the shell, meaning customers can crack them open easily using the tool provided.  

The challenge the business faced was automating the placement of the keys into bags during the filling process. The manual method was cumbersome and inefficient. It involving a worker standing on a ladder for prolonged periods of time and physically placing a key into each bag.  

Shifting from manual to automated processing was a no brainer. The manual task was repetitive and posed obvious safety risks — that’s not to mention the monotonous nature of placing up to 20,000 keys into bags each day.  

The goal of the automation project was clear: create a system that would both crack the problem of manual labour inefficiency and improve safety. The requirements included automatic pick and place of up to 60 keys per minute, seamless integration with the existing production line and a minimal factory floor footprint.   

Solutions from Shibaura Machine 

To meet the requirements, the Freedom Fresh team enlisted automation experts, M.A.P Services , the authorised Australian distribution partner of TM Robotics and Shibaura Machine industrial robots. 

 The M.A.P Services team selected the THE400 robot as the foundation for the system. The THE series is a flagship SCARA robot range from Shibaura Machine — formerly known as Toshiba Machine until a corporate name change in 2020. The THE series is among the latest robotic launches from the Japanese manufacturer and an ideal choice for pick-and-place applications.  

“The THE400 met all of the requirements for the Freedom Fresh project,” explained Nigel Smith , managing director and CEO of TM Robotics. “With a 400 mm arm length, the robot is relatively compact and requires minimal factory floor space. It boasts an impressive cycle time of 0.39 seconds with a 2 kg load and accurate movement trajectory with high-speed operation.”  

The robot was equipped with the TS5000, a high-speed, precise robotic controller from Shibaura Machine. M.A.P also integrated an IFM O2D camera for vision processing and an IFM encoder for conveyor tracking, with SMC vacuum gear handling the pick-and-place mechanism. 

An automated pick-and-place process  

With this equipment now installed, the automated process begins with the IFM O2D camera monitoring a continuous stream of keys on the conveyor. Upon triggering, the camera captures an image and uses its in-built contour detection to locate each key. The camera then sends the position of each key to the robot controller via TCP/IP Ethernet communications. 

“Integrating the vision system and encoder with the new generation TS5000 controller presented some initial teething issues,” explained Smith. “However, the user-friendly interface of the controller and the Shibaura Machine robot teach pendant made the integration process significantly easier. Our robot experts worked collaboratively with M.A.P Services to ensure seamless integration.” 

The robot syncs with the IFM encoder for accurate conveyor tracking, picks up the key with a suction cup and carries it to the drop point. There, it waits for a signal from the nut-filling machine before releasing the key. This cycle repeats every second, ensuring a high-speed operation that leaves no room for error or delay. 

Installation and results  

The project exceeded all expectations. The automated system exceeded the cycle time requirement, achieving higher efficiency and reliability. In fact, Freedom Fresh Australia expressed immense satisfaction with the solution. 

“Our experience with the new system has been an eleven out of ten,” explained Trevor Steinhardt of Freedom Fresh Australia. “The job of placing keys into bags was a difficult one, and there was no mechanical solution we could find. Now, the system just runs. It is coping very nicely and the strike rate is far better than a human operator.”  

Joel Spiteri , the engineer from M.A.P Services that installed and commission the system added, “The first robot installation took place in July 2023, and it has performed flawlessly ever since. What’s more, the impressive results led Freedom Fresh Australia to order three more identical systems. Two of these robots are designed to work in tandem, further increasing cycle times and productivity. The additional robots were installed in early 2024 and are currently in the final stages of commissioning.” 

 When detailing the success of the project, Spiteri cited several factors. “First, the advanced technology of the Shibaura Machine SCOL, combined with the precision of the IFM O2D camera and encoder, which ensures accurate and rapid key placement. Second, the seamless integration of the THE400 SCARA robot with the conveyor tracking system and vision system to facilitate smooth operation.”  

The collaboration between TM Robotics and M.A.P Services was also noted as instrumental to the project’s success. Throughout the design, installation and commissioning stages, M.A.P Services and TM Robotics maintained a collaborative approach. Regular online meetings facilitated effective communication and problem-solving.  

“Lastly, it was the customer-centric approach that delivered outstanding results,” added Spiteri. “We ensured that we understand and addressed the specific needs of Freedom Fresh Australia. This effort led to a tailored solution that has exceeded the customer’s expectations.” 

Future prospects 

Encouraged by the success of this project, Freedom Fresh Australia plans to further explore automation opportunities in its production processes. While automating processes like this one can be a tough nut to crack, leaning on the local expertise of M.A.P Services and the support of Shibaura Machine distributor, TM Robotics, for robot consultation can be the ‘key’ to achieving success.  

By employing a 6-axis industrial FANUC robot to automate the palletising of its bottled salad dressing line, Swiss condiment producer Brunos has alleviated production inefficiencies, allowing the company to keep pace with its growing order book.

Founded in 2001, Brunos produces cooled salad dressings and gourmet butters. Since its inception, sales have risen steadily, prompting this progressive family business to employ increasingly sophisticated production methods to keep up with demand. Now a 45-employee enterprise, Brunos produces four million products each year at its 3,500m² production facility in Sarnen, central Switzerland.

Although its production line was already automated, until recently, Brunos’ packaging and palletising function was still a manual process. This resulted in bottlenecks at the final stage of the process, as employees struggled to match the speed of the automated line. Unable to meet increased order levels and at the limit of its capabilities, the firm began to look for an alternative solution – but complex palletising patterns and limited space made their search a potential challenge.

“We had reached our limits,” explains Managing Director Michael Arnold. “By this point, we had two or three employees packing bottles manually into cardboard boxes, but they could hardly keep up with the speed of our production line. We began thinking about an automated solution for the palletising process, but our space was rather tight. We needed to find a solution with a compact footprint that would tie in with our existing automated processes in terms of quality and productivity.”

Fulfilling complex palletising patterns

Brunos turned to Robotec Solutions AG, a local provider of robot-assisted automation, with more than 800 successful installations to its name across a diverse range of sectors. Jörg Lanz, Head of Sales at Robotec Solutions AG, says: “Working together with our customers, our most important task is to find the best automation solution for the application. In this project to palletise the bottled salad dressings, our main challenges were cycle time, space constraints and palletising patterns.”

With regards to the palletising patterns, Brunos’ production line fills bottles individually before placing them in groups of 6, 10 and 12. These groups then undergo shrink-wrapping in foil. “We needed to devise an innovative palletising pattern based on the pre-grouping of bottle packs and involving part-rotation,” reveals Jörg. “After completing each layer, we required the robot to place an additional intermediate layer on top. This operation would have to take place without changing the gripper to help minimise cycle time.”

Strong, long and lightweight

Robotec regularly leverages the quality of FANUC’s range of industrial robots and collaborative robots (cobots) to fulfil its customers’ requirements. In this instance, the ideal robot for the task was the strong, lightweight and compact FANUC M-710iC/50 6-axis industrial robot with 50kg payload and 2,050mm reach.

“It was clear from the start that we would choose a FANUC robot,” states Jörg. “We’ve been a FANUC partner for over 20 years and often say we have ‘yellow blood’ flowing through our veins. The FANUC M-710iC/50 fits Brunos’ requirements perfectly. Capable of carrying heavy loads, its long reach allows optimal processing of the palletising pattern – and always at full speed. Further plus points include low energy consumption, a small footprint and good availability of spare parts.”

Increasing capacity

For Brunos, automating its palletising function with the help of the FANUC M-710iC/50 robot has allowed it to keep pace with the production line, enabling the company to fulfil its ever-growing order book. Michael Arnold adds: “We are very happy with the results and success achieved following the introduction of the FANUC robot. It fulfils our expectations in terms of quality and productivity. We are completely satisfied.”

Check out the video here: https://www.youtube.com/watch?v=t9KOhG0ZYuM

All-electric injection moulding machines have many excellent qualities, including greater precision, higher power density and lower carbon emissions. Yet there’s a preconception that these systems are more expensive to repair. Ashlee Gough, Area Sales Manager at Sumitomo (SHI) Demag UK delves into and discredits the top five myths regularly encountered.

1. Capacity planning is a moving target

Struggling to stay on top of everything is one of the greatest challenges for production engineers. Yet, Mean Time Between Failure (MTBF) is one of the simplest reliability measurements for polymer processors. It is also probably the most valuable KPI for equipment-reliant operations as it provides an accurate method for measuring machine availability, and helps with the planning of maintenance schedules, as well as capacity planning.

With fewer moving and wear parts, the time-lapse between one failure to the next is significantly less on all-electric moulding machines. Proving this, a study of the overall machine MTBF on a Sumitomo (SHI) Demag IntElect2 under warranty was on average 4.4 years – double that of an equivalent hydraulic machine. 

This MTBF metric is not just attributed to the machine design, but also how well an operative repeatedly handles or interacts with this valuable asset. A poorly executed repair job or implementing a quick fix and running the machine until it finally goes bump can just as easily result in a low MTBF result.

2.    Same or similar service time

Electric machines are less mechanically complex. With no flexing of hoses, no sensitive valves, perishable seals or hydraulic fluid, the risk of an emergency callout is significantly lower.  

Studies conducted by Sumitomo (SHI) Demag revealed that a 130 ton hydraulic machine operating 24/5 needed 39 hours of routine service work, compared to just six hours for an equivalent IntElect2 model.

Analysing and treating oil in order to maintain its optimum properties, as well as changing the oil filter, are essential routine maintenance task on hydraulic systems. The timing of these tasks  are critical and any delay or neglect can drastically increase the risk of machine failure.  Performing a filter change to the proper standards realistically takes a couple of hours. If an oil change or complete flush through is required, this not only results in unplanned downtime but also comes at a great expense.

Additionally, hydraulic hoses should be regularly inspected. It is recommended that they are replaced every ten years. Contamination and airlocks are always a danger when replacing hydraulic hoses. Because of this, it is recommended that this work should be undertaken by a professional.

Hydraulic machines with accumulator technology should ideally have the bladder replaced periodically. Inspecting the accumulator housing for cracks every ten years using x-ray is equally advisable. 

3.    Drives are expensive to repair

Typically, all-electric machines have the reputation of being expensive to repair when they go wrong. This view is often based on the cost of replacing an entire drive system.

Many moulding machine suppliers source their all-electric drives from external OEMs, which makes it more challenging to source component replacements, exchange or access service support. In the best-case scenario, moulders might be able to source and switch out a power or control module. Yet in most instances, sourcing a new complete drive is the reality, which of course, runs at a premium cost.

That’s one of the key reasons why Sumitomo (SHI) Demag has an R&D centre dedicated to drive development and designs and builds its own drive motors, designed purely for injection moulding machines, in-house. Being able to source individual replacement boards is a more sustainable solution for customers. Spares are also held for immediate shipment.

Drives that are designed to be modular are also much more cost efficient. Why replace three power modules, when you can replace just the one that’s failed? It can be the difference between several hundred pounds and a quick fix, rather than a complete drive replacement which could run into a few thousand.

4.     Infrastructure savings takes a long time

The savings when switching to all-electric are instant and can often be significant. Because each axis of an all-electric injection moulding machine is independently controlled, parallel functions are possible. This means that they can perform multiple tasks at once, for example ejection during mould opening or ejector retraction during mould closing. Resulting in faster cycle times which significantly increases productivity, output and component quality.

The increased efficiency delivered by direct drives means that they use considerably less energy than hydraulic machines – in the case of the IntElect between 40% and 85% less than conventional solutions. As electric drives generate less heat than their hydraulic

counterparts, they require less cooling than conventional machines of a similar size. Additionally, the recovery of kinetic energy while the clamping unit is braking generates energy which can be used for plastification.

This not only reduces the burden on existing infrastructures but also lessens the investment when building or relocating to new premises.

5.   Wear and tear is a guessing game

Reducing costs, risks and disruption are high on the priority list of many moulders aiming to achieve optimum processing efficiency, with machine reliability being the most influential factor.

Regardless of machine type, it is imperative to monitor and routinely service moving parts, e.g. toggle systems, seals or bearings, which are subjected to varying degrees of wear and tear.

It is often easy to identify wear on mechanical components via sensory diagnosis – surfaces may appear worn/scored, it may sound out of place or it may smell “hot”. However, electrical systems can often be overlooked as it can be very difficult to diagnose wear on electrical components such as electrical drives, motors, contactors, relays and PCBs. A moulder often won’t be aware of an issue until the machine stops. Thermal imaging offers a big advancement in this area.

Regular thermal imaging checks of electrical cabinets can give an early indication of impending component failure and are a quick and cost-effective way to spot potential issues early on. 

The use of thermographic equipment for condition monitoring is included in Sumitomo (SHI) Demag’s annual activeCare check. Rather than a ‘best guess’ diagnosis, activeCare engineers can assess the collected data and determine when equipment or parts are likely to fail in service.

The biggest mistake moulders can make is discounting high-performance all-electric machines on price alone.  The price difference between hydraulic and all-electric injection moulding machines has dropped considerably over the past 15 years. When considering the potential energy savings, productivity improvements and prolonged reliability, further total cost of ownership savings can be realised. 

For all-electric machine service costs, the studies speak volumes with the facts outweighing the fiction.

Ashlee Gough from Sumitomo (SHI) Demag UK dispels 5 misconceptions about all-electric moulding machine costs.

Thermal imaging a direct drive can provide a good indicator of any inefficiencies, heat emissions and even wear and tear.

Stand 4900, Farnborough International Airshow, 22-26 July 2024

Factory automation specialist FANUC UK will showcase a suite of next-generation automation solutions at Farnborough International Airshow to enable higher rate aircraft and aerospace manufacturing. Spanning the entire supply chain – including solutions for the burgeoning eVTOL sector – visitors to stand 4900 can witness the future of aerospace manufacturing first-hand. FANUC’s automation demonstrations, in conjunction with their industry leading partners, will cover a variety of key applications essential for the aerospace sector such as dispensing, polishing, inspection, machining and drilling, helping manufacturers to meet increasing order levels by boosting productivity.

Futureproofing to increase output rates

The aerospace industry is booming. Commercial revenues are expected to grow 14% year-on-year over the next 10 years, while passenger traffic will grow by 3.6% annually up to 2044. Around 22,120 new aircraft will be delivered between 2024 and 2033 – this equates to nearly 200 a month, every month, for the next 10 years.

“While this is great news for the industry, it means that manufacturers will need to find ways to increase production rates,” says Oliver Selby, Head of Sales at FANUC UK. “Operations have to be more streamlined and cycle times must be cut, all while maintaining the highest standards of quality and safety.”

Flexible future of the factory floor

Flexibility in manufacturing will be another key element in the industry’s successful growth. To this end, the FANUC stand will feature the University of Nottingham’s world-class OMNIFACTORY project. A five-year, £3.8 million facility that employs advanced technology and methodology to make manufacturing more efficient and cost-effective, OMNIFACTORY is a bespoke test-bed floor which autonomously adapts to the next product’s environment and specifications. The demonstrations around the project’s AGV show a combination of digital technologies, robotics and artificial intelligence including robotic surface preparation and dispensing. The aim of this proof-of-concept project is to inspire a new generation of smart, highly efficient factories, embedded in local supply chains.

The power of partnerships

A variety of automated systems from some of FANUC’s key partners – each employing FANUC robots at the heart of their technology – will also be on display at the event. One such example is an advanced metrology solution from Hexagon. Showing how data can be used throughout the product lifecycle to accelerate aerospace innovation and efficient manufacturing, Hexagon’s Presto Robotic Metrology system dramatically cuts the time required to devise inspection routines, by reducing them to a single step. Built on leading scanning technology, this flexible, modular cell has been designed to effectively meet the evolving needs of modern manufacturing. 

Meanwhile,an aerospace drilling cell developed by Electroimpact and featuring a FANUC CRX-25iA cobot, will demonstrate accessible and cost-effective pre-validated drilling functionality for the aerospace sector, offering improved reliability, repeatability and traceability compared to manual practices.

The growth of eVTOL

Finally, with the eVTOL sector being a key focus at this year’s event, FANUC will also showcase its ROBODRILL vertical machining centre, featuring a Nikken 5AX-201 tilting rotary table. This combined machining and turning cell enables difficult to hold components to be rapidly mounted and changed, even where space is limited.

“With a compact footprint, this is a perfect, cost-effective solution for small castings, using aerospace grade alloys, for products like eVTOL motor housings,” Oliver explains.

To learn more about the future of aerospace manufacturing, visit FANUC on stand 4900 at the Farnborough International Airshow, 22-26 July 2024.

Factory automation specialist FANUC UK will showcase a suite of next-generation automation solutions at Farnborough Interantional Airshow to enable higher rate aircraft and aerospace manufacturing.

An aerospace drilling cell developed by Electroimpact and featuring a FANUC CRX-25iA cobot will demonstrate accessible and cost-effective pre-validated drilling functionality for the aerospace sector.

FANUC will also showcase its ROBODRILL vertical machining centre, featuring a Nikken 5AX-201 tilting rotary table.