Sirris manufacturingday2011 flexible-robotising-robo_job

Flexible Robotizing for small and medium

sized runs

Brief introduction Aluro Group company’s

Analyses of the evolution making industry = genesis of RoboJob

List of requirements

Illustration of our results

Q&A

9/05/2011 1Helmut De Roovere

Reception General. IT-infrastructure Accounting & Finance Reporting

Bending Alu-profileswww.bestbend.com

Subcontractor Mechanical partswww.aluro-cnc.com

Equipment insulating profileswww.aluro.com

Aluro-Group companies

Easily automate your CNCwww.robojob.be

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Competition on international level

Prices dictated by a global market

Benefits & Handicaps when producing in Belgium

….

Our customers work in International markets

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Small variations by the end consumers lead to amplified variations every step downwards the supply chain

Industry 2011 = Supply chain

Production companies must be SUPER flexible, smaller lotsizes, rapid manufacturing of prototypes, shorter lead times, ….

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Internal capacity mechanical parts

Market demand

Time

Overtime, weekendwork, work during vacation, recruitment, (over-)

investments,…STRESS

Tempory unemployment,dismissals, insolvency,…STRESS

Recources

24h x 360 days = 8640 h

14h x 220 days = 3080 h

Machine capacity

Operator capacity

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a glimp at our labour market

Evolution of labour cost in Industry

Gross added value per person Productivity upcoming economies

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Schrink of our working population

Evolution of Gross margin

1995

Market tariff CNC work 60,- €/h

Labour cost CNC operator -22,- €/h

Depreciation of CNC machine -12,- €/h

Tooling cost -5,- €/h

Gross margin 21,- €/h

2010

60,- €/h

-38,- €/h

-12,- €/h

-5,- €/h

5,- €/h

• Over a period of 15 years, decline of gross margin by 76% !!!!!!!

• Attempt to compensate this by having one operator servicing more machines

• This is harder & harder to achieve by rapidly changing volumes & rising product flexibility

• Consequences are , increasing pressure on production companies and their workers

• As this tendency is rising, our work environment becomes more & more unappealing ,

• Attempt to maintain gross margin by working longer with machines, or working with only second hand machines

• Doing so is only a temporary solution, on a longer term this is pernicious

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Summary of analyse

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+ Supply chain demand for great product- & volume flexibility

+ Our production output is based & depending on labour

+ Labour is not flexile, expensive and hard to get

+ Our labour population is general declining

+ Our labour cost is too high

+ Our productivity seems to stagger, we’ve reached the limits

+ Our gross margin declined with +70% over the last 15 years

MARKET CHANGEMENTS ARE DRAMATIC

Solution is urgent needed

Our goal at RoboJob

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2010

Market tariff CNC work 60,- €/h

Labour cost CNC operator -38,- €/h

Depreciation of CNC machine -12,- €/h

Tooling cost -5,- €/h

Gross margin 5,- €/h

30% is set-up related

70% is related to production output

Small & medium lot-sizes

We aim to cut this labour factor

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Integrated Robot System-Chuck Work

What we developed …

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Easy to integrate on existing CNC machines

Usable for a RANGE of products (cfr. Range of CNC)

Compact solution, workspace = limited & expensive

CNC easy accessible for operator

Very short set-up time < 5 minutes for new product

Set-up by CNC operator NOT by Robot programmer

Re-usable on other machines

Re-usable when extending to decentralized automation

Results within normal working hourswhen making small & medium batches

1995

Market tariff CNC 60,- €/h

Labour cost operator 22,- €/h

Depreciation of CNC 12,- €/h

Tooling cost 5,- €/h

Gross margin 21,- €/h

2010

60,- €/h

38,- €/h

12,- €/h

5,- €/h

5,- €/h

2011 + RoboJob

60,- €/h

13,- €/h Only for Set-up

12+6=18,- €/h Additional depreciation

5,- €/h

24,- €/h Back in business !!

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In a 2 shift environment; 220 working days x 7,6h per shift= 3344 h per machine per year

30 % of operator time is set-up related = 1003h/year

Remaining time = production time (3344-1003=) 2341

During this production time you can create extra gross margin of (24-5=)19€/h

On a year this is extra gross margin of 44.479,-€ per CNC machine

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Possible extra results, nights, weekends, NO vacation,…

220 working days x 8 h per night = 1760 u per machine per year 44 workweeks x 2 weekend days x 24 u = 2112 u per machine per year Total additional intrinsic capacity = 3872 u per machine per year This is more than during normal working hours 3344) !!!!

0 €

20,000 €

40,000 €

60,000 €

80,000 €

100,000 €

120,000 €

140,000 €

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Possible additional gross margin

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An industrial Robot is a durable resource :

The utmost flexible automation component

A proven uptime of 99,99%

A proven life expectancy of + 15 year

IRS-CW system is a durable resource which :

Even by small- & medium sized batches

Can be put at work immediately WITHOUT SPECIFIC ROBOT KNOWLEDGE

Set-up time < 5 minutes for new parts, < 3 minutes for repetitive parts

Disconnect invoice hours from labour hours (70% disconnection by small & medium s.)

Takes away production pressure from operators , this brings peace in your company

Multiply your gross margin by 3 during normal working hours

Immediately makes your potential capacity available in a structural way

Guaranteed pay-back time < 2 years within normal working hours

Potential pay-back time of 6 months

Can be put at work 24h/day , 7 days a week

Works for free after 5 years

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