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Company Presentation 2015
- 1. The Automation Professionals Page1 Clever Solutions, Low Cost Production
- 2. The Automation Professionals Page2 Contact Details • Company Name The Automation Professionals P/L ABN 96 087 163 924 • Contact : Mach CaoXuan Engineering Manager • Address 42 Valenti Crescent Kellyville 2155 NSW Australia Phone/ Fax: +61 2 88147258 Mobile: 0416 558 775 Email: mcaoxuan@tpg.com.au
- 3. The Automation Professionals Page3 Master Degree in Mechanical Engineering of University Stuttgart Germany (1979) Germany: – 1979 – 1987 : BMW (Germany) - Advanced Manufacturing Engineer Robotics and Assembly Automation – 1987 – 1991 Digital Equipment (Germany/USA) - Senior Manufacturing Engineer Introduction of Cleanroom Production / Manufacturing Technology – 1991 – 1996 Schlumberger (Germany/France) - Project Manager Design & Implementation of a modern, highly automated assembly line Australia – 1996 – 1997 Parker Hannifin - Industrial Engineer Production Supervisor – 1997 – 1998 Pierlite P/L : Project Manager Design and implementation of an automated production line for light fitting products Blue Point Products P/L: Project manager Design and implementation of a flexible, fully automated electric link bars production line Unistrut P/L: Consultant: Implementation of cost reduction measures – 1998 The Automation Professionals founded Design and Build several automated machines for Atlas Plastics (plastic bottles manufacturer), DANA (car components), Antec (Building material supplier), Sandler (Shoe manufacturer), Matchmaster (Antenna Manufacturer), Pathfinder Systems, Dorf Clarks, Cochlear ( medical devices manufacturer) , etc. - 1999 – 2002 Swisslog Australia P/L Senior Logistics Design Consultant for Warehouses and Distributions Centers - 2002 – 2003 Webb Conveyor Company P/L Division Manager “ Warehouse and Distribution-Automation” - 2004 – 2008 Woolworths Limited Distribution Center Design Manager - 2008 – 2011 Logistics Bureau – Logistics Consultant - 2011 - 2013 Xact Solution – Logistics Consultant Mach CaoXuan - Engineering Manager
- 4. The Automation Professionals Page4 Manufacturing Division Product Design: Design for Manufacturing / Design for Assembly – Analyze current product design and recommend suitable changes to reduce cost and to simplify manufacturing/assembly process (Design For Manufacturing /Design for Assembly). Production : Improve productivity – manual or automated production – Analyze current production methods and processes • Identify production bottlenecks • Develop conceptual solutions for productivity improvement • Estimate total cost of implementation and the potential saving – Design and Build production equipment and assembly systems • Work out detailed solutions • Provide detailed CAD Drawings of equipment and machines • Build and Install Production Equipment ( manual or automated - Jigs and Fixtures, Robot systems, Material Handling devices etc.) – Project Management • Write detailed project specifications and tender documents • Evaluate quotations / Vendors and System Suppliers • Supervise project from conception to commissioning – Review technical documents (drawings, user manuals, maintenance contracts, etc.) – Specify requirements for all necessary tests – Supervise installation and commissioning – “Turn Key” System: • We design, build, test and commission completed solutions • Low-Cost option: working with client’s tool shop, electricians etc.we can achieve a cost saving of up to 40% compared to full turn key •Can we design products with less parts? •Can we reduce material cost? And eliminate scraps? •Can we simplify the production processes? •Can we design products suitable for “affordable” automation? • Can we eliminate non-value added operations? • Can we shorten cycle time? and increase output? • Are we applying the right production technologies? • How can we improve working conditions (ergonomic)? • Should we consider automation and how much will it cost? • Are the proposed solutions technologically “proven”? • Are we selecting the “right” vendors? Do they have after sales service? • How can we minimize project risks? Do we have the resources for intensively following and checking project progress from the beginning on?.
- 5. The Automation Professionals Page5 Services/ Logistics and Warehousing Section • Analyze current Warehouse and Storage System (2 -4 weeks) – “Check Up” Analysis – Observation, Workshops and Discussions • Assessment of the current storage and material handling equipment • Identification of issues and problems • Providing practical advices on short term solutions and benefits • Recommendations of long term strategies (optional) • Design Distribution Centers (DC): – Assist clients collecting and structuring Warehouse Data – Carry out Data Analysis: Key Design Parameters – Develop alternative solutions for all function areas of the DC from receiving to despatch. Evaluate and select the most suitable solutions. – Search for applicable Warehouse and Material Handling Equipment – Develop detailed Warehouse Layouts – Develop the “Day in the Life” analysis of the planned DC • Material Flow • Product Slotting • Utilization ( staging areas, storage capacity, etc.) • Calculate the Labour Cost per Carton • Estimate total Investment Typical questions : •Why our Warehouse is always so congested? •Why our KPI is too low compared to known standards? •Is the current storage method the most “space- effective” one? How can we solve our current acute space problem? • Which material handling equipment can be applied to “speed up” warehouse operations? •Are we applying the right picking strategies? •Why so many picking mistakes? •Are there ways to reduce our cost per carton? •How can we improve the safety level? Expected results: • Detailed CAD drawing of the new DC • Facility Sizing- Layout • # of receiving docks, # dispatch docks • storage systems (storage zones, storage unit loads, storage system design (selective or high density, aisle width, storage handling equipment • Order picking systems (breakcase, fullcase, discrete or batch picking sortation, RF, Voice, etc.) • MHE parking, battery charging room, • maintenance workshop, production facilities • Safety • List of all needed equipment • Equipment Utilisation (average/peak) • Number of required direct employees • Labor cost per carton
- 6. The Automation Professionals Page6 References Manufacturing Section
- 7. The Automation Professionals Page7 Reference : Gasmeter Assembly Line (Client: Schlumberger – Germany) • Fully automated assembly line • 16 Assembly Stations • Pallet Conveyor System • •Technologies: • Assembly Robots & grippers • Leakage Test • Automated Glue Dispensing • Packaging • Total Investment: 3.5 Mio DM • Saving: • On Labor Cost Before: 80 Assemblers After: 20 Assemblers On Material Cost: Before: 110 DM After: 70 DM
- 8. The Automation Professionals Page8 Integrated Production Line for Light Fitting (1998 / Pierlite Pty Ltd – Australia) Solution: • Product Redesign for Automation • Applying new joining technology (Tox) (eliminating screws and nuts) • Reducing number of parts ( 30% less) • Simplifying production process: • by using pre-painted metal (eliminating painting) • conveyor system ( eliminating transport and handling) • Fully integrated production process • Punching and Rollforming • Assembly and Testing • Packaging and Palletizing • Total Investment: AUD 0.9 Mio •Saving: On Labor: 14 Assemblers On Material : > AUD 3 /unit The Automation Professionals was responsible for product redesign, concept solutions, detailed project specification and project management. The machine system was built by Premiere Rollform ( Decoiler, Punching Press, Rollforming machine), Applied Robotics (Assembly Station, Palletizing machine) and Solary Packaging (Packaging
- 9. The Automation Professionals Page9 Flexible, fully automated production Machine for “link bars” (1999 / Blue Point Products Pty Ltd - Australia) • Product variations: • Different lengths ( 30 mm to 200 mm) • Different holes patterns • Applied technologies • Cut to lengths • Drilling and Tapping • Marking (Inkjet Printing) • Screw Inserting • Quality Checking • Counting •Total Investment: 0.7 Mio AUD •Saving: Before: 10 Operators per shift (total 20 per day) After: 3 Operators per shift (total 6 per day) Return On Investment : about 1 year The Automation Professionals developed concept solutions, wrote detailed project specification and managed the whole project from supplier selection, design verification to supervising installation. The machine was built by Broens Toolmaking
- 10. The Automation Professionals Page10 Nail Inserting Machine 1999 / Pierlite Pty Ltd Tool for nail “inserting” Before: • Two Operators “hammered” nails into plastic parts using hand hammers. • Major concerns: • Frequent Injuries (fingers) • Poor Assembly Quality • Low production output Solution: • A Bowl Feeder separates and feeds nails into a “mouth-piece” of a specially designed pneumatic “hammer” • Another Bowl Feeder transports plastic part to insertion station • Pneumatic hammer presses nail into plastic part • Linear Feeder conveys assembled parts into packing cartons •Total Investment: AUD 60,000 • Saving: Before: 4 Assemblers After: 1 Operator (supervisory task) Return On Investment: < 6 months The machine was designed by The Automation Professionals and built by Pierlite’s Tool Shop Personnel.
- 11. The Automation Professionals Page11 Design Study :Assembly Line for Food Dispensing Products 2003 NJ Phillips / Gosford Objectives: •To reduce labor cost per unit by 50% •To increase production output (1000 – 1200 units) •Investment should not exceed AUD 200,000 with a Pay Back of 1 – 1.5 years Solution: • better balanced assembly line • improving ergonomic condition of manual assembly stations • re-use existing equipment • low cost automation The design study was carried out by The Automation Professionals. Realisation planned in FY 2004
- 12. The Automation Professionals Page12 Design Study: Redesign Lighting Product 2003 / Thorn Lighting Pty Ltd Objectives: : •Redesign product to reduce material cost and simplify assembly Initial Situation: • Cost of the “body” of Thorn’s High Bay product is high because of: • 40% scrap • Excessive material handling effort (tool changes, palletizing, transport) Solution: New design of “body” • Reduce scrap from 816 cm2 to 144 cm2 • No tool changes • Stacking of flat sheets instead of palletizing of folded products (saving on storage and transport) • Improve assemble-ability Calculated Saving: approx. $3 per unit The study was carried out by The Automation Professionals. old proposed
- 13. The Automation Professionals Page13 Design Study: Tap Head Assembly Machine 2002/ Dorf Clark Industries Pty Ltd Objectives: • Fully automated assembly •To increase production output by 10% •Investment should not exceed AUD 150,000 with a Pay Back of 1 – 1.5 years Solution: • re-use existing equipment • low cost automation The design study was carried out by The Automation Professionals. extension Existing machine
- 14. The Automation Professionals Page14 Label Application June 2003 / Impresstik Pty Ltd Initial Situation: • Impresstik received an urgent order to supply special labels • Labels to be applied from underneath on a sticky protecting film • > 20,000 labels/h • Application Equipment to be designed and built within 3 weeks Solution: • Labels are stacked manually in magazines • A ‘twin-heads” picking arm mounted onto a pneumatic rotary cylinder enable picking and applying four labels in 0.5 sec. •Total Investment: • AUD 12,000 (design and pneumatic products) • Fabrication and Assembly by Impresstik tool shop The machine was designed by The Automation Professionals and built by Impresstik’ s Tool Shop Personnel.
- 15. The Automation Professionals Page15 Pallet Elevator and Conveyor Dec 2003 / DANA Spicer Initial Situation: •Two workers remove empty pallets (12 kg) at the end of an automated assembly line, and carry them to the start of the line located 25 meters away. Solution: • A pneumatic elevator lifts empty pallets to a overhead conveyor at 2500 mm high level . • The conveyor then conveys pallets 40 meters to a 2nd elevator • The 2nd elevator lowers pallets to transport level at 900mm high . •Total Investment: • AUD 120,000 The machine was designed and built by The Automation Professionals. Inventcom Pty Ltd was responsible for all electrical and programming works
- 16. The Automation Professionals Page16 Automated Station for Shoe In-Sole Marking Feb 2004 / Sandler Shoes Initial Situation: • Four (4) workers mark lines on shoe “in sole” • Poor quality Solution: • Store Shoe soles in stack magazine • A rotary handling unit picks one sole from magazine and brings it to marking station • Two axis Robot marks lines on shoe sole. •Total Investment: • AUD 40,000 • Saving: 3 workers • Return on Investment < 1 year The machine was designed and built by The Automation Professionals
- 17. The Automation Professionals Page17 Assembly Jig July 2004 / Antech Engineering Initial Situation: • Six (6) workers hammer plastic caps onto two ends of wire anchors • Injuries to fingers/ lost of production Solution: • Automated feeding caps to inserting station • Worker places anchor into inserting station • Pneumatic cylinder presses cap onto anchor •Total Investment: • AUD 20,000 • Saving: 3 workers • Return on Investment < 1 year The assembly jig was designed and built by The Automation Professionals
- 18. The Automation Professionals Page18 Helix Winding Machine December 2004 / Cochlear Initial Situation: • Operators need 4 -5 hours to complete an extremely complicated assembly job • Reject Rate > 50% Solution: • Semi automated assembly jig reduced assembly by more than 90%, total time is 5 minutes. • Reject rate reduced to 0% •Total Investment: • AUD 40,000 The assembly jig was designed and built by The Automation Professionals.
- 19. The Automation Professionals Page19 Welding Machine November 2005 / Cochlear The Automation Professionals was contracted by Cochlear in 2005 to develop a prototype for an automated precision welding machine: - One axis high precision robot arm (5 microns) - Selectable welding programs - Cleanroom Environment
- 20. The Automation Professionals Page20 2009 - Semi-automatic drilling machine Installation of Tactile Indicator on Rail Station Platform Initial Situation: • 48,000 holes need to be drilled to install tactile indicators on a 200 meters long rail platform. It takes 400 hours. Solution: • Semi-Automated Drilling Machines • 12 drilling units • manual push to index •Time to drill 48,000 holes: 20 hours per machine 10 hours per 2 machines •Total Investment: • AUD 60,000 (two machines) • Saving: 390 hours or 23,400 $ per installation (based on hour rate of 60$ per hour)
- 21. The Automation Professionals Page21 Completed Design Projects Tube Assembly Jig (2005) Pneumatic Inserting machine Glue Application (2006) Drilling Robot
- 22. The Automation Professionals Page22 - Blue points products P/L: - Study: Facility Planning and Manufacturing Strategies - Study: Evaluation and Selection of CNC machine centers - Design: Manipulator Gripper for Glass Tubes - Unistrut ( Mt Druit) - Project: Design and Installation of a Gantry Crane for quick changing of rollers (rollforming machine) - Study: Measures for Improving Productivity . - Dorf Clark (Milperra): - Specification for Press Line Automaton - Design: Robot Tool for polishing kitchen sinks - Dorf Clark (Penrith): - Design, Build a device for loading wash machine - Design, Build a Fixture for O-Ring Assembly References (cont.)
- 23. The Automation Professionals Page23 References Logistics Section
- 24. The Automation Professionals Page24 Distribution Center - Pharmaceutical Products The Philippines - 2001 • Approx. 40,000 sqm • Two DC under one roof • Mainly” breakcase picking” • Pick to totes on belt sortation • Pick to Light • Weight Checking
- 25. The Automation Professionals Page25 Factory Layout 2003 / Atlas Plastics Pty Ltd The Automation Professionals has been contracted by Atlas Plastics for designing layout concepts for the upgraded factory. Objectives of the project are: - Optimizing Storage System: Increasing storage capacity , improving accessibility - Reducing Operating Cost by Grouping Machines, Implementing Conveying system and simplifying packaging operations
- 26. The Automation Professionals Page26 Distribution center - Grocery Thailand - 2005 • 50,000 sqm • Average 100,000 cartons/day – peak : 180,000 c/d • Required storage capacity : 60,000 pallets – High Density Drive In Rack – Pallet Flow Rack – Selective Rack • Pick from Pallets to Pallets : (Fast Moving SKU) • Pick from CLS to tote : Breakcase – Slow Moving • Bulk Pick: PLS module
- 27. The Automation Professionals Page27 Implement Layer Picking for fast moving products Australia - 2006 - Identify product suitable for layer picking - Analysing carton characteristics - Analysing layer dimensions and weights - Analysing business requirements to ensure that the layer picked volumes are beneficial to - DC : improve pickrate from 150 to 1200 c/h - Customers (Stores): received quantities are manageable - Carried tests - Purchased complete layer picking system (forktruck and attachment) - Tested to ensure that layers can be picked up by a “Cascade” layer gripper - First Layer picking implemented in 2008.
- 28. The Automation Professionals Page28 Design and Build : Turnstile – Dock Safety Australia - 2007 - Safety Issues: - Fork trucks fall off raised dock levellers cause injuries to drivers and costly damages to equipment - Solution: - Turnstile Dock safety - Allow dock leveller to function - Keep fork trucks within a safe, operational zone - Woolworths decided to installed the designed turnstile in all receiving docks .
- 29. The Automation Professionals Page29 Design an Empty Pallet Removing Mechanism (EPRM) Australia - 2008 Initial situation: • The process of handling empty pallets (removing from pick slots, transporting to a pallet stacking point, building pallet stacks) is purely manual • This process have been identified as a major SHE (Safety Health and Environment) concern and BigW has contracted the Automation Professionals P/L to develop a mechanism allowing handling empty pallets with ease. Solution: • A semi-automated, low cost pallet retrieval device mounted on a manually pushed overhead guide rail. Motorized components allow effortlessly • Picking up pallets • Rotating to bring pallet in an upright position • Stacking up at stacking point • Patent pending
- 30. The Automation Professionals Page30 Distribution Center - Retailer Australia - 2009 • > 90,000 sqm • Average 120,000 c/d – peak : 200,000 c/d • > 50,000 reserve locations – High Density Drive In Rack – Pallet Flow Rack – Selective Rack • Pick to Belt – Batch Picking Modules (Slow Moving SKU) – CLS on ground level – PLS on 2nd and 3rd levels with EPRM • Pick to Pallets (Fast Moving SKU) • Carton Crossdock • Cross belt sorter (8000 cartons/h) • Bulk Pick: PLS module • Work load “balancing” Storage: 12 deeps PLS • Automated wrapping
- 31. The Automation Professionals Page31 Distribution Center - Energy Equipment supplier Australia - 2010 • 25,000 sqm • 4,000 pallet racking locations – selective rack • 2000 Shelving bays • Cantilever rack for cable conduits • Handling large cable drums • Racking for Drums • Semi-automated cable cutting • 30 T overhead crane • Truck Loading/Unloading • Handling heavy loads (>25 T)
- 32. The Automation Professionals Page32 Total DC Area: 11.400 m2 Office on Mezzanine 275 m2 Number of docks 23 Function Areas: Receiving staging / Dispatch staging Bulk Pick Non-conveyable picking Pick module for slow and medium moving items Sorter Forklift parking/ Battery Charging Distribution Centre - Fast Food Company The Philippines - 2011
- 33. The Automation Professionals Page33 Distribution Centre - Spare Part Supplier Australia - 2012 • Proposed layout change - increase storage capacity - increase # picking slots - more staging space for receiving and despatch - Improve accessibility
- 34. The Automation Professionals Page34 Cross Dock Center - Food Delivery South Korea - 2012
- 35. The Automation Professionals Page35 Distribution Center - Retailer Australia - 2013
- 36. The Automation Professionals Page36 Distribution Center - Retailer South East Asia 2015 • > 100,000 sqm • > 60,000 reserve pallet locations – High Density Satellite System – Selective Rack • Zone Picking _ Pick to Totes (Unit Pick &Slow Moving SKU) – CLS for “faster” moving SKU – Shelving for slow moving SKUs • Pick to Pallets (Fast Moving SKU) • Pallet Crossdock
- 37. The Automation Professionals Page37 - Swisslog : - DC Design Studies for several customers in Malaysia, Singapore, China, Philippines. - DC Design (concept); Coca Cola Melbourne / Australia (2002) - Webb Conveyor System - Developed an automated car storage system for Mitsubishi Adelaide (2003 - Webb then was awarded the project ) - Woolworths : - DC Design Study: Extension of the Brisbane Regional Distribution Center (2008) - DC Design Study: Refurbishment strategies for two 15 year old, highly automated DC (2007) - Operation Trial: High Rise Order Picking (Man Up). (2006) - BigW : - DC Design Study: Facility for handling optical products (2008) - DC Design Study: Modification of existing sorters to suit increase demands (2006) - Poly Industries: - Installation of High Density Racking (2000) Other projects
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