Case study: considering whether to invest in automating the production of a given part
Model example
We want to produce 60,000 parts per year, first machined on an SP 430 turning centre and then finished on an MCV 1000 milling centre. We are considering whether the investment is worthwhile.
Without a robot | With robot | |
|---|---|---|
Required production capacity per year | 60 000 pcs | 60 000 pcs |
Working hours per year (350 days, 4 shifts) | 8 400 h | 8 400 h |
Production efficiency | 62% | 91% |
The introduction of automation eliminates operator downtime. The robot always has a semi-finished product ready for the fastest possible changeover, thus increasing production efficiency. Production efficiency is dependent on machining times, handling times (robot or operator) and machine adjustments (tool changes, etc.).
Production time of the SP 430 | 12 min | 12 min |
|---|---|---|
Calculated number of SP 430 machines | 2.5 | 1.7 |
Required number of machines SP 430 | 3 | 2 |
Production time of MCV 1000 | 5.8 min / piece | 5.8 min / piece |
Calculated number of MCV 1000 machines | 1.2 | 0.8 |
Required number of machines MCV 1000 | 2 | 1 |
Required number of operators / shift | 3 | 1 |
Annual salary (400 000 CZK / operator) | 4 800 000 CZK | 2 544 192 CZK |
Due to the higher production efficiency, the number of machines needed is lower and the number of operators per shift is also lower.
Investments in robotics | 4 250 000 CZK | |
|---|---|---|
Investment in SP 430 machines | 13 590 000 CZK | 9 060 000 CZK |
Investment in MCV 1000 machines | 7 446 000 CZK | 3 723 000 CZK |
Total investment | 21 036 000 CZK | 17 033 000 CZK |
Cost of materials | 31 CZK / pcs | 31 CZK / pcs |
|---|---|---|
Tools + energy for one piece | 15 CZK / pcs | 15 CZK / pcs |
Required return on investment in years | 3 | 3 |
Price / part | 243 CZK | 167 CZK |
Cost difference per workpiece | 31,1 % | |
Economic effects of automation:
- Increases production efficiency
- Increases production productivity
- Reduces input investment (fewer machines needed)
- Reduces personnel costs (fewer operators needed)
