In the new era of intelligent manufacturing with diversified customer groups and increasingly strong personalized demand, more and more enterprises have an urgent need for automation transformation and upgrading, and they are also very interested in flexible production lines. However, the doubts and concerns of "too high investment" and "too long return period" have always troubled them.
So, how much investment is needed to lay out flexible production lines and realize automation upgrading?
Let's make an account for you.
Flexible production line
Let's look at the costs of traditional manufacturing mode
Labor cost - a machine tool needs to be equipped with one worker;
Labor cost: manual transportation of materials, fixtures, etc;
Time cost - workpiece switching, clamping, setting changes lead to idle equipment;
Time cost: machine tool waiting due to finding / allocating blank, fixture, tool, NC program and other materials;
Time cost: machine tool waiting or damage caused by wrong or missing process documents and data transmission;
Time cost: the equipment is damaged and stopped, the workers rest, and the machine tool is shut down;
Time cost - multiple tool calls increase the risk of errors or deviations, resulting in the processing of scrap parts
……
Low utilization rate of machine tool:

The waste of equipment waiting and time cost which can not be estimated and avoided makes the equipment utilization rate of traditional manufacturing mode greatly reduced, and the total annual cutting time of enterprises is also greatly reduced.

Again, compare the flexible automation production mode
Saving labor costs - one technician controls multiple devices;
Save labor cost - automatic transfer of materials, tools, etc;
Save time and cost - the automatic production line produces 24 hours a day, which is not affected by workers' rest and reduces equipment downtime;
Save time and cost - intelligent production management software can automatically calculate the production resources required to meet the order according to the order, balance the production tasks automatically, arrange orders automatically, and reduce the waiting time of machine tools;
Saving time and cost: centralized management of NC program (program version), tool detection and tool life management ensure the normal operation of unmanned night shift;
Save time and cost - keep the tray in its position, avoid positioning error caused by continuous setting and correction, ensure the quality of workpiece and reduce the cost of waste products
……
All weather production:
Flexible production line can make full use of the working time of the machine tool, realize unattended "turn off processing" at night shift, greatly improve the utilization rate of equipment, increase the total annual cutting time, and develop the production potential of the enterprise to the limit state.
Comparison of return rates
Based on the calculation of two five axis horizontal machining centers, the cost return rate of traditional manufacturing mode and flexible automation mode is compared.
*Calculation based on two five axis horizontal machining centers
**50 weeks, 5 working days per week, 2 shifts per day (+ 1 unattended automatic processing)
***Loss of spindle operation time caused by no manual preparation + unattended third shift
As for the return on investment in flexible automation, according to the big data analysis of the return on investment of automation system application customers in the past 30 years by fastems, the world's leading flexible automation solution provider, the big data analysis shows that the return period of investment in automation cost is between 1.3 and 3 years; more than 60% of European customers choose to further extend the application of automation system within 2 years For example, adding equipment into the production line, adding more storage locations, adding loading stations, or software upgrading, etc.
In fact, flexible automation is not a new concept. Its rudiment appeared as early as the 1960s and has been developing vigorously in Europe and the United States since the 1970s. At present, with the rapid progress of control technology and information technology, as well as the continuous optimization of production organization and management mode, flexible manufacturing system has been a set of very reliable, stable and efficient system, and can be reasonably constructed and expanded according to the actual use needs of enterprises. At the same time, the cost investment has been greatly reduced compared with the past.
Since the first flexible production line was developed in 1982, fastems has continuously innovated and developed flexible automation product technology with the concept and goal of "helping users realize the full utilization of 8760 hours (365 days x 24 hours) of machine tools". We are able to provide various types of modular standard and customized flexible manufacturing systems, as well as full service life. No matter what production target you need to achieve, our solutions can help you to maximize the productivity of machine tools, improve profits and reap benefits.
​​