Robot packages deliver growth for aerospace sector

According to a report from PwC about the outlook for the aerospace sector, Boeing has more than 400 737 MAX aircraft to deliver and plans to ramp up production of that model to 31 per month in 2022.

Airbus also plans to increase production of A320s to 45 per month by the end of the year.

Managing director of REM Systems, UK and Eire agents for Erowa automation systems, Ian Holbeche, comments: “The long-term forecast for commercial aerospace appears very positive. For example, 82% of the global population has yet to set foot in an aircraft so there is an enormous untapped segment of new customers. This adds up to a significant increase in the delivery demands placed on the supply chain.

“To help meet demand, retrofitting an Erowa robot to an existing lathe, machining centre, mill-turn or even a combination of these machines in a cell will allow any machine shop to operate effectively around-the-clock. Investment in an Erowa Robot Easy or Robot Compact 80 can achieve a very quick payback. Making the most of the available production time and keeping companies competitive.”

The Erowa Robot Easy 250 offers a small footprint, from only 3m². The Robot Compact 80 fits within a 2m² footprint and can lift up to 80kg. Both robots are suitable for side and frontloading installations making them flexible enough to fit into any available shopfloor space.

Everything required to ensure the automation system runs perfectly is included in the retrofit package. It comprises an air dock system that allows 5-axis machines without a compressed air supply for the chuck on the machine table to be reliably automated and a Robodoor for machines without an automatic door along with machine interfaces between the machine and the handling robot which are configured to suit any application.

After installation employees also receive comprehensive training in the use of the new automation system to ensure the business gains the expected benefits.

An optional addition to the package is the Erowa JobManager JMS 4.0 ProductionLine. This practical online process control system provides automatic management of machines and loading robots, within the concepts of Industry 4.0 or the Smart Factory.

This provides machine shops using chip-cutting production with significant advantages: it provides a clear view at all times of every workpiece being processed, their exact locations and how far into the process each is in real-time. It links up all the data and controls the entire production process and its software connects machines with the widest variety of manufacturing technologies.

Mr Holbeche states: “By using automated loading, a machining centre typically runs much more economically. The hourly output increase by a factor of three or more.”

Putting forward a simple calculation highlighting the benefits of a retrofit robot package, he says: “Let’s compare a CNC machine tool investment of £300,000 against the additional investment of £85,000 required for the retrofit package. Without automation on a single shift with an operator the machine has 1,500 available hours. The overhead cost will be around £80 per hour with a charge out rate of £100 per hour, the payback period is around six years, a 9% ROI.

“With the robotic automation and the same single shift operator, the machine’s available hours increase to 5,800 per year. This reduces the overhead cost to around £35 per hour and allows the business to reduce the charge out rate to £70 per hour, thereby increasing the competitiveness. This results in a payback period of less than two years which equates to an ROI of over 80%.”

Every application is different but exact calculations for any machine shops’ ROI can be provided by REM Systems’ experienced staff.

Mr Holbeche concludes: “Given the current extended waiting times for new machine tools that can lead to capacity shortfalls, these could be addressed by an Erowa Retrofit Robot Package. Robotic automation also supports the environmentally conscious principles of making the most of what you have – effectively making more with less.”  

REM Systems
www.remsystems.co.uk