Robotics and Automation for SMEs

Supachai Vongbunyong, PhD Assistant Director of Research and International Affairs Institute of Field Robotics (FIBO) King Mongkut’s University of Technology Thonburi Co-Founder of Innovation and Advanced Manufacturing Research Group

TOPIC

1. Introduction to Robot & Automation

2. From manual to automatic

3.Industrie 4.0 - Physical Transformation

4.Case-study

5.Transformation strategy

Levels of Automation 1. Introduction to Automation and Robotics

Identify the level of automation in your manufacturing system

Levels of Automation 1. Introduction to Automation and Robotics

Level Load Machine

Cycle

Unload Part

Transfer

1 M M M M

2 M A M M

3 M A A M

4 A A A M

5 A A A A

Ref - โครงการยทุธศาสตร์การเพ่ิมศกัยภาพอตุสาหกรรมไทยดว้ยระบบการผลิตแบบอตัโนมตืั

Identify the level of automation in your manufacturing system

M = manual

A = Auto

Ref - http://electrical-engineering-portal.com/automation-migration-strategy-in-3-phases

Phase 1 Manual

production

Phase 2 Automated production

Phase 3

Automated Integrated production

Levels of Automation - Phases 1. Introduction to Automation and Robotics

“In Korea, Germany and Japan, there is a ratio of 270-400 robots for every 10,000 human workers “

1. Introduction to Automation and Robotics

Thailand is one of the rapidly growing robot markets in Asia

http://www.ifr.org/industrial-robots/statistics

Estimated yearly

shipment of multi-

purpose industrial robots

(Number of

units)

Robot Population 1. Introduction to Automation and Robotics

Pro

du

cti

on

Vo

lum

e

Product Variety

Robotics

https://somemmec.wordpress.com/2013/03/09/what-are-different-types-of-

automation-or-compare-hard-automation-and-soft-automation/

Robots and Fixed Automation

1. Introduction to Automation and Robotics

• Payload: very high

• High accuracy

• Not flexible

• Easy to program

• Payload: 3-20 kg

• Fast

• Good for pick-and-place

• Payload: 3-2000 kg

• Highly flexible

• Advanced

programming

Articulated

Delta

• Payload: < 3 kg

• High speed

• Small payload

Industrial Robots 1. Introduction to Automation and Robotics

SCARA Cartesian

Automation Migration Steps

2. From Manual to Automatic

•Identify your current position & Needs

•Optimize process → Operation research

•Identify the opportunity for automation

•Feasibility study → People, Resource,

•Investment & Implementation → partial, full production line

Players in Migration – (1) People

• Vision of the executive • Resolve workers problems

– Skilled workers – Health and safety

• Prepare people in automation –Operate –Maintenance – Develop

2. From Manual to Automatic

Players in Migration – (2) Resources

• Automation suppliers – Equipment and parts – Technology availability and feasibility

• Source of knowledge & consultant – Academic institutes – System Integrators – Makers & Vendors

• Research & Development – Internal & External

2. From Manual to Automatic

Players in Migration – (3) Investment

• Return of investment • Technology feasibility

• Government Programs

– Tax incentive on R&D and process improvement

– Tax exempt on import - export

– Super Clusters in robots and automation

2. From Manual to Automatic

Case-study: Bayak

3. Case Study

1. Identify your current position & Needs

- “High quality water for every one”

- SME

- Production of 18.9 Lt Water bottle

- Automated Integrated Production Line (12 Bottle /minute)

- Manual Load-in/out to trucks

Case-study: Bayak

3. Case Study

1. Identify your current position & Needs

Problems

- Logistics cannot be optimized

- Manual Load-in/out is too slow (3 Hrs / 200 Bottle/ truck)

- Operators encounter health problem with back

- Difficult to find the labor

Case-study: Bayak

3. Case Study

2. Optimize process

- Utilize alternative storage system – ProStack

- Improve workflow in load-in/out

Case-study: Bayak

3. Case Study

3. Identify the opportunity for automation

- At the load-in/out process, change from human to robotics

- Improve productivity and workflow

Existing automated loading system

Case-study: Bayak

3. Case Study

4. Feasibility study

Benefit

– Social aspect Labor health, cost, and welfare

– Economic aspect Improve productivity

– Technology aspect low-cost system design

Current

(Manual)

New

(ProStack + Robot)

Load-in truck 3Hr / truck 20 mins/ truck

Load-in Prostack N/A 12 Bottle/ Minute

Number of operators 3-5 person 1 person

Health of operators BAD GOOD

Case-study: Bayak

3. From Manual to Automatic

5. Investment & Implementation

– Solution consultant

– Government program

– Project implementation

Advantages of Industrie 4.0

● Improve productivity

● Zero waste and zero errors

● Collaborative workplace

● Sustainability

Enterprise Resource Planning

Plant Management

Process Control

Machine and Field

source of pic - http://www.zi-argus.com/mis-mes.php

4. Future Smart Factory in Industrie 4.0

Smart Factory

Institute of Field Robotics (FIBO) - King Mongkut’s

University of Technology Thonburi - Industrie 4.0

4. Future Smart Factory in Industrie 4.0

Cyber Physical Systems Framework

● Internet of Things

● Cloud Technology

● Big Data

Cyber Physics

● Smart Automation

● Smart Robots

● Hardware

Sensors Network

People

Fixed Automation Mass Customization in Smart Factory

4. Future Smart Factory in Industrie 4.0

Transformation Strategy

Identify needs and consult

Utilize tax exempt policies

Business – Technology matching

5. Transformation Strategy

Transformation Strategy

Government Programs and Incentives

• ITAP - http://www.itap.nstda.or.th

• NIA - Technology to Capital - http://www.nia.or.th

• BOI – Tax Incentive

• Super Cluster - Robotic and Automation

• Talent Mobility

Institute of Field Robotics (FIBO) - King Mongkut’s

University of Technology Thonburi - Industrie 4.0

5. Transformation Strategy

At FIBO

• Education – Curriculum is designed to produce integrators, innovators, and researchers that are ready for Industrie 4.0

• Research – Smart robots and automation

– Big data management & analytics

– Cyber-physical system and

• Industrial services –Big data platform for large organizations

–Smart manufacturing system

5. Transformation Strategy

Industrial Service at FIBO

5. Transformation Strategy

“Think of Robotics and Automation, Think of FIBO” http://fibo.kmutt.ac.th

5. Transformation Strategy

Industrial Service at FIBO

Conclusions 5. Transformation Strategy

Industrial Service at FIBO

Conclusions 5. Transformation Strategy

Industrial Service at FIBO

Thank You

Dr. Supachai Vongbunyong

Website:

Innovation and Advanced Manufacturing Research Group

http://www.fibo.kmutt.ac.th/iam

Email:

supachai_von@fibo.kmutt.ac.th