Page 24 - MetalForming June 2012

Laser-Cutting Automation
parameters. An MLC can provide pro- duction data that identifies what was cut, when it was cut and how long it took to cut.
Material unload—Similar to mate- rial-storage and loading options, fab- ricators can select from numerous con- figurations of fixed and scissor-lift tables for handling completed sheets. It is not uncommon to combine multiple offload tables so like-parts can be
stacked. The MLC can direct the tra- verser to move specific parts to a par- ticular table. Tables can ride on a rail system so they can be pulled from the cell for unloading without endangering operators. (Although we’re not address- ing fences, interlocks and other safety apparatus here, the machine manu- facturer will specify the safety equip- ment necessary to comply with gov- ernment safety regulations.)
Storage towers also can be added to an FMS, to enable separation of fin- ished work. Configurations and capac- ities are similar to the variety of load- tower options.
As you design an automation sys- tem, plan for growth and consider workflow layout, including material loading, unloading and other operations.
4) What Challenges Lie Ahead?
While implementing a laser- automation system will have a dra- matic impact on throughput, when incorporating existing laser-cutting machines into the system do not underestimate the lost production capacity during system build and inte- gration. Also, carefully consider down- stream operations relative to workflow and capacity.
Skilled labor also is an important component of the plan. While auto- mated-system operation will require fewer operators than will standalone machines, a few skilled people are crit- ical to oversee effective operation and to maximize throughput. Training must be a core element to implementation. Production expectations should grad- ually ramp up as the system comes online.
With a laser automation system fully operational, expect a dramatic impact on downstream operations—bending and welding, for example. Where laser cutting might have caused a bottle- neck, automation will eliminate it. But, if capacity for downstream operations does not increase, the bottleneck will simply shift. Therefore, you must devel- op a plan for handing the increased volume of laser-cut workpieces await- ing secondary operations. Initially, you may need to pace the lasers based on a pull approach from bending, welding and other downstream operations.
A final consideration is the attitude of everyone affected by the automa- tion system. Employees may fear for their job security, or mourn the loss of overtime hours. Gaining a certain amount of buy-in from the shop floor will enhance the likelihood of a suc- cessful project. MF
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