Case Study

Case Study: Robotic Sprayer Increases Consistency andReduces Waste
Application: Painting / Spraying
Robot Model: Kawasaki RS080N general purpose robot

OVERVIEWIn the eyes of some manufacturers, installing an industrial
robot can seem intimidating. Misconceptions of having torebuild everything from the ground up and having to adopt
a completely new process can make automation seem like abigger endeavor than it truly is. In reality, there are many
ways to embrace automation without starting from scratch,and the available resources make programming andmaintaining a robot possible for all knowledge levels –including first-timers.
Baton, LLC, a Louisville-based manufacturer of AirStone
faux stone veneers and siding, learned this firsthand when
they installed their first robot with the help of Dakswan
Automation. Once implemented, the Kawasaki RS080N
general purpose robot helped Baton cut down production
time and significantly reduce waste, with minimal changes
made to their existing production line and tooling.

For manufacturers whose products are constructed in harshenvironments, it can be difficult to retain employees, and thattask is even more challenging during an industry-wide labor
shortage. This lack of consistency can lead to low production,and is a primary reason why Baton decided to automate theirspraying process.
Minimal process changes only
The RS080N was Baton’s first robot, so the manufacturer wasKHVLWDQWGXHWRFRQFHUQVWKDWWKLVQHZHTXLSPHQWZRXOGEH
disruptive to the process they’d developed over the past fiveyears. Dakswan needed to design a customized solution thataligned with their customer’s manual process“It took years to develop our spray system that applies color
into our product, and the manual gun we use works well for anumber of reasons. It would have been hard to replace”, Tom
Scanlan, Owner and President of Baton, LLC said.

CHALLENGESë,QFRQVLVWHQWPDQXDOSURFHVV\LHOGVKLJKDPRXQWVRIZDVWHë8QIULHQGO\ZRUNHQYLURQPHQWIRUHPSOR\HHV
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Product inconsistencies
In order to produce AirStone prior to automation, fourSDLQWHUVVSUD\HGOLTXLGFHPHQWRQWRPROGVDVWKH\approached on a conveyor. Each painter used a different
amount of material, resulting in inconsistent products andover use of materials.
“Human un-friendly” environment:RUNHUVZHUHUHTXLUHGWRZHDUUHVSLUDWRUPDVNVZKLOH
spraying the molds to remain safe and minimize exposure
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Kawasaki RS080N robot, retrofitted with a paint gun, sprays liquid cement
into faux stone molds on conveyor.

SOLUTIONUTION
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H.DZDVDNLODUJHSD\ORDG generaleral purpose RS080N robot installedë%XLOWLQ3/&RSWLRQ./RJLFXVHGWRFXWOWLQ3/&RSWLRQ./RJLFXVHGWRFXW
ts and streamline operations
costs
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customer’s
tomer’s existingproduction
duction line, tooling andprocesses
cesses
The robot is positioned in thesamee place as the workers werepreviously.
ously. When the partsarrivee in front of the robot on
a conveyor,nveyor, the robot isprogrammed
rammed to paint at thesame
e speed as the humanworkers
ers before it, but therobot’s
t’s ability to work all
day without breaks saves Baton anaverageage of 2.5 hours of downtime each week.

Case Study

Choosing a robot from Kawasaki’s line of high performance
general purpose robots, as opposed to paint robots, was apurposeful choice by the integrator, who picked this specificmodel due to its long reach capabilities. The RS080N robot’s
extended reach (2,100 mm) made it perfect for Baton’s
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from one fixed location.

Although Baton is technically a first-time robot user, theNQRZOHGJHWKHLUPDLQWHQDQFHVWDIIDFTXLUHGIURPWKH
Operations & Programming training course they took at
Kawasaki’s training center has enabled them to keep theirrobot up and running smoothly entirely on their own.
Additionally, they are able to reprogram the robot to testout different spraying patterns for new products.

Kawasaki’s R series robots are designed to be effective inworkspaces large and small. In addition to their extended
reach, the large rotation range of the R series’ axes
translates to a larger usable work area with minimal deadspace, so multiple robots can be installed in high-density
applications without impeding performance. The slim arm
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making them a great option for tight spaces, like Baton’s
paint booth.

After installing their RS080N robot to perform a “humanun-friendly” task, the benefits of automation showed
themselves in multiple ways throughout the company. Batonsaw a boost in production, so the workers who formerly
sprayed the AirStone molds were redeployed to the
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to harsh chemicals or protective gear.

Kawasaki’s option for a built-in PLC, called K-Logic, was
DQRWKHUPDMRUVHOOLQJSRLQWIRU'DNVZDQ$XWRPDWLRQK-Logic streamlines operations for the end user because allcommunication between the production line and the robot isdone internally. K-Logic also kept costs down by eliminating
the need for an external PLC, and minimizing the amount ofexternal cabling needed.
Same Process, ModernizedBecause the RS080N robot isn’t designed for performing
paint/spray applications, Dakswan designed a custom
end-of-arm tool to hold the exact same paint system theircustomer was currently using. This allowed Baton to retrofit
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over years of using this machine, and keep their end
product consistent with what they’ve sold in the past.
Dakswan installed the robot in the same place the humanworkers stood during the manual process, which meant%DWRQFRXOGNHHSWKHLUH[LVWLQJPDFKLQHU\DQGHTXLSPHQWLQ
WKHVDPHORFDWLRQDQGRQO\VPDOODGMXVWPHQWVQHHGHGWR
accommodate the new robot.

RESULTS“Since we hadn’t had any experiencence with robots, there
was apprehension (around) the robot
bot going down, howoften that could happen… or if (thee robot) was going tocause headaches with our manufacturing
cturing process, but
it’s been the opposite. It works everyday
wedon’tery day – we doon’nt
really have to do anything.”- Tom Scanlan, Owner & President, Baton, LLC
C

From an operational standpoint, Scanlan uses the words“worry-free” to describe using the new Kawasaki robot –despite his initial concerns as a first-time robot user.
“It was a very easy process to convert over from manual torobotic. Without a doubt, worth the investment,” Scanlan
said. “It’s been such an apparent positive to our plant… thereduction of material costs, reduction of downtime — all ofLW8VLQJWKHURERWLVMXVWNLQGRIZRUU\IUHHçFor Baton, automation didn’t mean overhauling a provenprocess or experiencing stress from complex programmingë:RUNHUVUHPRYHGIURPKDUVKHQYLURQPHQW UHGHSOR\HG
or unexpected shutdowns. The robot has improved theirto safer roles
manufacturing process while creating a safer work
environment for their employees. Dakswan Automationë3URGXFWTXDOLW\DQGFRQVLVWHQF\LQFUHDVHGVLJQLȖFDQWO\designed and implemented a cost-effective solution that
ë$PRXQWRIRYHUVSUD\UHGXFHG
utilized the machinery and tooling Baton had spent years
ë&XVWRPHULVSURJUDPPLQJDQGPDLQWDLQLQJURERWEDVHGRQ adopting, making for a seamless transition and a robotic
solution they are able to maintain entirely on their own.
knowledge gained from Kawasaki training courseë'RZQWLPHUHGXFHGE\KRXUVZHHN

Kawasaki Robotics (USA), Inc.
Corporate Headquarters for Americas
28140 Lakeview Drive, Wixom, MI 48393, U.S.A.
Phone: +1-248-446-4100 Fax: +1-248-446-4200

KawasakiRobotics.com