Producing perfect aluminium welds and eliminating harmful dust during polishing operations has been achieved by the acquisition of a series of CSF (Complete Surface Finishing) robotic solutions at Frontline Australasia Pty. Ltd. at their plant in outer south-east Melbourne.
The systems designed, manufactured and installed by CSF Australia using ABB robots, have produced a series of important benefits for Frontline, by greatly improving the quality of the welded aluminium products, while abolishing the dirty manual labour that was previously a by-product of the manufacturing process.
Frontline is a wholly owned Australian company that manufactures components for the defence and automotive industry. CEO Kevin Hooper explained that 30 percent of their production is for defence and 70 percent for the automotive market. “We manufacture locally fitted components for the automotive market sector; supplying original equipment manufacturers (OEM’s) including Toyota, Ford, General Motors, Mitsubishi and Kia.”
With the Australian manufacturing sector under extreme competitive pressures from suppliers in Thailand, Vietnam and China, the future of the local industry depends on the application of best available technology and the local expert knowledge base to remain viable. “Cost savings and annual productivity increases of 20 percent are essential for us to maintain the edge over imports” Hooper says.
“The ABB robots have produced a productivity increase of 45 percent, with another 20 percent in the pipeline over the next 12 months. We need to become more efficient, and industry players working in cooperation with governments and academia is an important partnership to offset the growing impact of overseas competition on the Australian manufacturing sector”, Hooper said.
The robots can handle an almost unlimited range of intricate welding patterns, with uniformly consistent quality outcomes. Turning to the relationship with ABB and CSF, Hooper described it as first class, with good technical backup and technical support, training, availability of spare parts and prompt service when the need arises, ensuring seamless operation of 20 hours a day, six days a week for the six ABB robots. The initial robot was purchased four years ago, with five additional units added over the last nine months.
Among these the following are operating at the Frontline plant: -
- 1 twin polishing robotic cell with two IRB 6640 robots
- 1 aluminium robotic welding cell with one IRB 2400 robot and Fronius Welding source
- 1 water jet robotic cutting cell with one IRB 4400 robot Foundry protected
Apart from the welding processes, Frontline, supported by a $ 1.5 million grant from the Federal Government, matched by similar amount by the company, has also developed a process of manufacturing titanium pipes, a process for which they hold global patents, to be price competitive with stainless steel pipes. This process can produce titanium pipes at a cost of about 25 percent of product currently available from existing technology.
“Using the latest technology, high productivity, trained staff, government and industry cooperation, all working together, is the doorway to the future of a viable and successful Australian manufacturing industry. In short ‘working smarter’ needs to be the catch cry to take us into the next decade and beyond”, Hooper said.
CSF DESIGNS INNOVATIVE MANUFACTURING SOLUTIONS
The close cooperation between Complete Surface Finishing Pty.Ltd. (CSF) and ABB was a very important element in providing the specialised technology that has provided the state-of-the art equipment to Frontline.
Frederick Kolak, the director of CSF described the development of the latest robotic applications as initially originating with the supply of robotic polishing cells” Polishing represents a major production cost, and area where robots can produce significant savings. This cooperation later evolved into the development of welding robots to handle the first mass produced bull bar line.
“One of the challenges was to design the software that would successfully weld two separate aluminium alloys, requiring different temperature setting, and allowing round-the-clock production”, Kolak said. “Our association with ABB, combined with our own expert staff provided the ideal combination to design, manufacture and install the robotic cells. ABB’s quality product, ease of usage, training and support is second to none”
Turning to robotics in general, Kolak said that designing and innovating new product applications is vital to keep work in Australia, as well as promoting export opportunities.
“We design and build innovative and unique products in working with industry. And while the actual robots are an important element in this, it is the people behind the design and software development that make it work. The robot is only as smart as the programmer”.
Kolak said there are opportunities for exporting to the Asian market, as our geographic location can provide short time lines of service, giving Australian based companies and expertise a distinct advantage over European suppliers in this region. CSF is currently working on a range of innovative projects, adapting robots to surface finishing, with R&D and software development a vital component for optimum benefit to industry.
Frontline Australasia Pty.Ltd. A privately owned Australian company was established in 1988, currently employs a staff of 145, with an annual sales revenue of $40 million. The company provides full design and engineering services using the latest CAE systems, manufacturing to Australian and international standards, and sees itself as a “high innovation” company at the cutting edge of technology. Awarded in top three automotive suppliers in Australia in 2009 judged by Ford, GM, Holden & Toyota
Its manufacturing base produces products for the defence market (30 percent) and automotive market (70 percent) with some 10 percent of export sales.
CSF Robotics (ABB Robotics authorised Partner), a division of Complete Surface Finishing Pty.Ltd., is a wholly owned Australian company, based in Melbourne. It was established a decade ago, when a small group of electrochemists and material scientists came together with the purpose of supporting industry with their decades of experience in electroplating, polishing surface preparation and robotic engineering. Their dedicated specialist staff creates innovative solutions to industry both in Australia and increasingly on a global market. Their products are sold throughout Australia, and are expanding with the main target throughout the Asia-Pacific area.