FANUC America marks the 35^th anniversary of manufacturing its line of painting robots at the company’s Rochester Hills, Mich., headquarters, a major milestone in the U.S. robotics industry.

Company President, Mike Cicco remarked: “We have dedicated ourselves to 35 years of product innovation and manufacturing efficiencies to provide our customers with the highest quality paint robots that we design, assemble, and integrate here in the U.S. and export to customers around the world. Throughout 2017, we will be taking a look at where we started, what we have achieved, and what our plans are for the future.”

In 1982, FANUC America produced its first NC Painter, a hydraulic paint robot using key components from parent company FANUC CORPORATION in Japan. Now, 35 years later, FANUC America remains globally responsible for all paint robots and door openers of the FANUC robot lineup, which are sold to a diverse range of industries including automotive, aerospace, agricultural products, recreational vehicles and boats, furniture, appliance, and medical devices. In fact, FANUC America has supplied its U.S.-made paint robots to all of the top 15 global automakers ranked by the International Organization of Motor Vehicle Manufacturers (OICA).

FANUC America’s U.S.-based product development team designs and implements a wide range of mechanical, electrical, process and software products, including Zero Down Time (ZDT), a cloud-based application that analyzes data collected from FANUC robots, alerting customers of potential issues that need to be addressed before unexpected downtime occurs. “Our local product development team is the industry’s largest with hundreds of years of accumulated engineering experience located here in Michigan,” added Cicco.

All of FANUC America’s new paint robots are ZDT-ready, which means they can monitor a variety of functions including paint canisters, spray applicators, drive health and paint process regulators. In addition, ZDT provides maintenance reminders to notify customers to inspect or replace worn items. Currently, there are over 800 paint robots now using ZDT analytics with additional robots connected to the cloud each month.

“Having an extensive group of local experts to provide software, product design, assembly and integration of our paint robots allows us to react quickly to customer needs,” said Jon Karr, FANUC America’s Vice President of Paint Shop Automation.

FANUC America’s paint robots are ideal for automating applications that are ergonomically challenging, hazardous and labor intensive. “We’re seeing a significant increase in paint robot sales to non-automotive customers both domestically and abroad,” added Karr. “These customers want to improve quality and throughput while minimizing their assembly workers’ exposure to hazardous environments, similar to what automakers looked to do back in 1982.”

FANUC America recently introduced its latest paint robot, the P-350iA/45, which will demonstrate sanding, washing and drying an aircraft fuselage at the 2017 Automate Show in Chicago, booth #1625.

The new P-350iA/45 robot is designed for a variety of applications including painting, coating, sanding, and washing, it offers a flexible six-axis design and is Class 1, Division 1 approved for operation in hazardous environments.

FANUC was named a GM Innovation Award winner during General Motors 24th annual Supplier of the Year awards ceremony held on Thursday, March 10th at COBO Center in Detroit, Mich.

GM debuted its Innovation Award to recognize five suppliers among thousands globally who brought new innovations to the company that benefit customers. FANUC was named a first-ever Innovation award winner for its Zero Down Time (ZDT) Application, which analyzes data from GM’s robots throughout its factories to detect potential problems that could lead to a failure. If a potential failure is identified, ZDT notifies GM and FANUC’s Service Center, so parts and support can be delivered to address the issue before any downtime occurs. FANUC America has released a YouTube video regarding the GM Innovation Award and FANUC Zero Down Time

“We partnered with Cisco to create highly secure connections from our robotic equipment in GM’s factories to Cisco’s Cloud Data Center where FANUC is able to perform analytics on how the robots are performing,” said Rick Schneider, Chairman and CEO, FANUC America. “The ability to collect data from our robots and analyze it in the cloud, to predict potential equipment issues before downtime, occurs allows us to proactively address our customer’s needs. With ZDT, we can also take advantage of the data collected from our robots to optimize GM’s manufacturing systems by reducing energy consumption, extending equipment life, improving cycle time and quality. Reducing downtime through ZDT has proven to have a direct and positive impact on GM’s plant’s performance.”

“With the FANUC ZDT solution, the robot is connected through a network and a Cisco data collector in the plant through to the Cisco cloud – all resulting in a sound and highly-secure solution end to end. By transferring the equipment data through a secure platform to the Cisco Cloud, Cisco and FANUC are building the manufacturing data highway, which will allow GM to collaborate with their large ecosystem of equipment suppliers and more easily perform preventive analytics and optimization with their equipment,” said Bryan Tantzen, Sr. Director, Cisco IoT Vertical.

Currently, FANUC has applied ZDT to thousands of robots in 27 GM factories in 5 countries. In addition to monitoring the robots for potential problems, ZDT keeps track of robot usage and sends reminders at appropriate intervals to ensure important maintenance activities are completed on time.

“We’re honored to receive GM’s prestigious Innovation Award,” said Schneider. “FANUC is committed to developing innovative, world-class products that provide manufacturers the ability to keep their production lines running uninterrupted.”

As a manufacturing equipment supplier, FANUC was the only indirect supplier (non-vehicle component supplier) to win the esteemed Innovation Award for the Zero Down Time solution.

During the event, GM also recognized 110 of its best suppliers from 17 countries who have consistently exceeded GM’s expectations, created outstanding value, or introduced new innovations to the company. FANUC was also selected as a GM Supplier of the year for the 11th year in a row.

GM recognized the most suppliers since debuting the Supplier of the Year event in 1992, representing a nearly 40 percent increase compared to 79 recipients in 2014. More than half are repeat Supplier of the Year winners from 2014.

“We are focused on building positive supplier relationships, bringing new, customer-centric innovations to GM, and being the OEM of choice among suppliers,” said Steve Kiefer, GM vice president, Global Purchasing and Supply Chain. “The companies we recognize tonight not only have brought innovation, they delivered it with the quality our customers deserve.”

FANUC CORPORATION, the world’s leading supplier of robotics and factory automation, is collaborating with Cisco, the worldwide leader in IT-enabled digitization, as well as Rockwell Automation, the world’s largest company dedicated to industrial automation and information solutions, and Preferred Networks, a leading provider of Artificial Intelligence solutions. The companies will work together on the development and deployment of the FANUC Intelligent Edge Link and Drive (FIELD) system, a platform that connects not only Computer Numerical Control machines (CNCs) and robots, but also peripheral devices and sensors – to deliver analytics that optimize manufacturing production.

The FIELD system will be a platform for the delivery of advanced analytics for FANUC CNCs, robots, peripheral devices, and sensors used in automation systems. It will drive improved machine reliability, quality, flexibility, and speed – elevating the Overall Equipment Efficiency (OEE) and increasing manufacturing profitability. It will also provide advanced machine learning and deep learning capabilities. By working with Cisco, Rockwell Automation, and Preferred Networks – FANUC will offer a complete solution including network and compute infrastructure, applications, and an enabling middleware platform. With this open platform — application developers, sensor and peripheral device makers, system integrators, and others can build solutions that improve equipment efficiency, manufacturing output, and quality.

Extension of Current Successes

The FIELD system extends the success of the existing FANUC ZDT (Zero Downtime) connected robots project; ZDT is built with Cisco cloud, IOT data collection software, and end-to-end security capabilities.

The companies are working together to implement systems for major automotive manufacturers by leveraging the Allen-Bradley Stratix Ethernet switches from Rockwell Automation to connect robots to a Cisco Unified Computing System (UCS) – all of this running on FANUC and Cisco’s ZDT Data Collection software. Automotive customers who have implemented this system are quickly realizing a significant decrease in production downtime as well as increased cost savings.

Intelligent Manufacturing

The FIELD system will bring the power of advanced machine learning and artificial intelligence into the hands of customers and application developers — driving manufacturing to a new level of productivity and efficiency. FANUC and Preferred Networks have established these new technologies for applications such as Bin Picking robots, anomaly detection, and failure prediction. The FIELD system combines both artificial intelligence and edge-computing technologies – enabling distributed learning. Data is generated from robots and machines and is processed in real time at the edge of the network. This allows those devices to intelligently coordinate and collaborate in a flexible manner – resulting in sophisticated manufacturing practices not before possible.

Who provides What for the FIELD System?

FANUC: Provides CNCs and robots with embedded sensors to track key variables required to improve machine reliability, quality, and speed.

FANUC, Cisco and Preferred Networks : Provides enabling middleware Platform Software, as well as security and application lifecycle management applications. It will also leverage Preferred Networks’ open deep learning framework (Chainer), IoT Stream Engine (SensorBee) – and other advanced machine learning libraries within its Deep Intelligence in-Motion (DIMo) platform.

Cisco and Rockwell Automation : Provides networking, compute and security infrastructure to connect the robots, CNCs, and other cell equipment to the FIELD applications. Based on the Rockwell Automation and Cisco collaboratively developed Converged Plantwide Ethernet (CPwE) architecture – this further drives improved security, connectivity, flexibility, and scalability – all of which allows connection from a single, small cell to a large factory with hundreds of cells.

FANUC, Rockwell Automation and Preferred Networks : Delivers the initial Application Software on top of the FIELD middleware and infrastructure platform. This will extend the LINK-i and ZDT applications currently deployed, along with additional deep learning applications from the FANUC and Preferred Networks partnership. It is planned that Rockwell Automation manufacturing software products (including FactoryTalk View, FactoryTalk VantagePoint, and FactoryTalk Production Center) will seamlessly integrate with the FIELD system to speed deployment.

LEADERSHIP QUOTES

Sujeet Chand, Senior VP and CTO, Rockwell Automation

“By collaborating with world class companies, Rockwell Automation helps maximize manufacturers’ investments by leveraging the data from their intelligent devices they are using today to drive an enterprise-wide analytics strategy. With a secure scalable compute approach to analyze this data – from device to the enterprise – users can improve operations and make more informed decisions tailored to meet the needs of their organizations.”

Rowan Trollope, SVP IoT and Applications, Cisco

“ This collaboration represents a historic shift in the industry, with IoT, industrial automation and machine learning coming together to make the factory of the future a reality. It’s been talked about for years, but now it is really happening. Cisco couldn’t be more thrilled to be a part of this effort, one that will be key to our positioning in other industries that want to realize the benefits of digitization .”

Toru Nishikawa, CEO, Preferred Networks

“PFN is excited that this collaboration will further accelerate the advancement of the manufacturing industry. Since the start of our work with FANUC, leveraging machine learning and artificial intelligence has been aimed not only at making machines and robots smarter, but also towards a continuous improvement of manufacturing productivity through intelligent real-time coordination and collaboration between robots and machines. We are confident that FIELD will play a central role in making that vision a reality.

FANUC America Corporation is introducing its new CR-35iA collaborative robot, the industry’s first 35 kg payload force limited collaborative robot designed to work alongside humans without the need for safety fences. The CR-35iA collaborative robot features six-axis articulation.  A soft foam green cover protects workers who are in direct contact with the robot.  The robot’s shell is green to distinguish the collaborative robot from the standard yellow FANUC robots. “The FANUC CR-35iA collaborative robot allows shared workspace between an operator and the interactive robot,” said Greg Buell, product manager, FANUC America. “The highly-sensitive robot gently stops if it comes in contact with the operator, allowing the robot and human to work side by side; in fact, FANUC currently has units running in production at General Motors.”

The CR-35iA robot was developed to help manufacturers solve ergonomic challenges by handling applications that are physically demanding for humans, such as heavy lifting.  In the automotive industry, for example, workers are required to lift spare tires into vehicles on the assembly line.  “The CR-35iA can work alongside the employees assigned to this task to help reduce injuries associated with repetitive or heavy lifting,” added Buell.

Certified to meet the requirements of ISO 10218-1:2011, FANUC’s CR-35iA collaborative robot can work in a variety of applications alongside human workers including: machine tending, handling heavy payloads that require lift assist devices or custom equipment, higher payload mechanical assembly, palletizing or packing, and tote or carton handling.

The CR-35iA robot offers a wide range of collaborative and safety features and benefits, including:

• Industry’s first 35 kg payload collaborative robot that can work with humans in a shared workspace without safety fences.
• Works in cooperation with a human operator in a variety of applications including assembly and heavy-duty   part transfer.
• Stops safely when it touches a human operator.

FANUC CR-35iA Collaborative Robot  

• Soft green cover minimizes impact force and prevents human operators from being pinched.
• Certified to meet the requirements of international standards ISO 10218-1.
• Supports FANUC’s latest intelligent functions such as iRVision.
• Designed with the same high reliability as FANUC’s conventional robots.

Next Generation R-30iB Controller

The FANUC R-30iB Controller uses high-performance hardware and the latest advances in network communications, integrated iRVision, and motion control functions.  The R-30iB Controller features FANUC’s exclusive and easy-to-use iPendant with 4D graphics.  The iPendant displays process information and the actual process path directly on the iPendant screen, enabling easier setup and troubleshooting.

Based on the latest FANUC Series 30iB CNC Controller, the R-30iB Robot Controller is compact, providing customers a significant space savings.  The R-30iB Controller is also energy efficient, requiring less power consumption than previous models, and available with an optional power regeneration feature.

Photo: FANUC America

FANUC America Corporation, the leading supplier of robotics, CNCs, and ROBOMACHINEs has been named one of Michigan’s top 100 workplaces by the Detroit Free Press for the third consecutive year.

The list of the best places to work in Michigan is based on employee responses to an independent survey conducted by The Detroit Free Press. Companies whose workers expressed satisfaction with workplace advantages such as pay and benefits, advancement opportunities, or flexibility of schedules make the top workplace list.

“We are honored to have been recognized as a top workplace for the third consecutive year,” said Karen St. Louis, director of human resources, FANUC America.

“As Michigan’s largest supplier of automation solutions for manufacturing, we take pride in having the industry’s most talented group of professionals, and continuously strive to achieve employee satisfaction,” added St. Louis.

FANUC America Corporation, the leader in CNCs and robots in the Americas, announces CIP Safety functionality with the new EtherNet/IP Adapter Safety function for the FANUC Series 3xi-B CNCs that enables safety communication with Rockwell Automation controller (Logix PAC) systems at Automation Fair 2014, Booth #151.

The new EtherNet/IP Adapter Safety function with CIP Safety is an enhancement to the current dual check safety function. The EtherNet/IP Adapter Safety function makes it possible to handle safety signals on the EtherNet/IP Adapter function, transferring safety signals between a master safety controller and CNC. It communicates digital input/output signals across Ethernet with high reliability to further simplify the hardware and connections needed.

Dual check safety on the FANUC Series 3xi-B CNC supports an integrated safety function over a single cable. Using built–in redundancy, a special processor monitors safety-related parameters and guarantees the integrity and safety of the system by tracking the actual position and speed of the servomotors, spindle motors and I/O interfaces.

Using the CIP Safety functionality of the new EtherNet/IP Adapter Safety function with dual check safety, the sending side device cross-checks the safety signals, adds the inspection data, and then transmits both data sets to the receiving side device. The receiving side device ensures integrity and safety by confirming the inspection data and cross-checking the safety signals.

The initial release of EtherNet/IP connectivity allowed for open interconnectivity of FANUC CNCs to factory automation solutions. The use of EtherNet/IP network architecture allows customers to leverage common tools and technology for device configuration and maintenance across CNC, robot and Logix PAC cell environments. Benefits of this include: a simplified, lower cost architecture, improved productivity and actionable information across the entire manufacturing enterprise.

With CIP Safety functionality in the new release of EtherNet/IP Adapter Safety function, end-users and machine tool builders will additionally benefit from the added integrated safety communication between CNC and Logix PAC control environments as well as further simplification of the hardware and connections.

This new function was specifically designed to communicate between a safety controller and CNC with safety signals for automotive transfer lines. The FANUC and Rockwell Automation integrated automotive architecture, demonstrated at Automation Fair 2014, Booth #151, will show the complete benefits to customers including; simplified architectures, faster startups, improved synchronization between platforms, lower maintenance, integrated safety signal communication, improved productivity and transparent data access across the entire connected manufacturing enterprise.

FANUC CORPORATION, the leading manufacturer of CNCs, robots, and ROBOMACHINEs, has been named one of the top 100 innovative companies in the world by Forbes. This is the fourth consecutive year Forbes has named FANUC a top global innovator.

Forbes 2014 “The World’s Most Innovative Companies” list recognizes leading-edge corporations that are most likely to be innovative now and in the future. The Forbes innovation list is based on a study completed by professors and advisors who determined that calculating a company’s value plus anticipated growth fueled by new technology and products will identify the most innovative companies. A key factor used in compiling this list was each company’s commitment to R&D. Embedded in each of these companies is a code for innovation discernible in their people, processes and philosophies that drive them to keep innovation alive year after year. The end result is that innovation will create demand for their products now and in the future.

FANUC features the Power Motion i-MODEL A motion controller for high performance, multi-axes general motion applications at the Assembly Show, Booth #1425, October 28-30, 2014, Rosemont, IL. The Power Motion i-MODEL A is an integrated solution supporting up to 32 axes of high performance motion control, combined with high speed programmable logic controllers supporting up to 2048 input and 2048 output points. Users trust FANUC’s superior control and servo technology, reliability and support for machine tools, and now they can have that same performance and value for their general purpose motion control equipment.

The Power Motion i-MODEL A provides a variety of standard screens for setup, operation and maintenance and an easy high-level motion path programming system. It provides fast, low-cost application development, an integrated motion specific architecture that provides a highly competitive hardware cost for multi-axis applications, as well as the reliability and performance that delivers the lowest total cost of ownership.

The Power Motion i-MODEL A offers multi-axis and multi-path functionality for a maximum of 32 total control axes that can be grouped in up to 4 independent control paths, each path containing a maximum of 24 axes; 4 axes simultaneous motion. Alternatively, up to 16 axes can be individually controlled directly by the programmable logic controller. Advanced functions allow flexible motion control of axes by position, speed, torque or pressure.

A broad range of highly customizable display solutions are available to meet application needs including integrated LCD screens, standalone solutions supporting multiple screens and sophisticated hand-held displays that are ideal for teaching or operations close to the application.

The Power Motion i-MODEL A integrates seamlessly and quickly into production systems with the widest range of field network support. Communications with business systems, manufacturing systems and robots are achieved easily with embedded Ethernet.

General industrial motion control machine applications include: winding machines, wire saws, gantry loaders, die cushions, press machines, multi-axes positioning systems, large robotic positioning tables, wing riveting machines and polishing machines. Ideal for large servo applications that replace hydraulic mechanisms, the Power Motion i-MODEL A reduces cycle time with a high-speed response function for quick axis start/stop and high-speed execution cycle of programmable logic control. Additionally, integrated safety is available to meet specific industry and European standards.

Makino has been honored by FANUC Robotics America with its 2013 Outstanding Sales Growth Award. The award was presented at the company’s Integrator Conference in March, and demonstrates the record volume of new robotic automation cell installations that Makino Engineering Services performed.

“We are incredibly appreciative of the award and our relationship with FANUC Robotics,” said Dave Walton, integration services manager at Makino. “The Makino Engineering Services group is constantly working to build stronger relationships with automation partners in order to provide customers with the highest degree of technology, service and support. This award is an affirmation that we are meeting these goals and raising the bar for automation integration and engineering support.”

These automated systems are supporting companies across North American in driving business growth, improving quality standards and achieving greater profitability and global competitiveness.

Makino Engineering Services
Makino Engineering Services has an unmatched history of creating robust production-ready processes—including machinery, fixtures, tools, programs and documentation—for parts with complex geometries, demanding deadlines, challenging budget constraints and Six Sigma standards. Hundreds of manufacturers in need of integrated manufacturing systems have taken advantage of these services—each benefiting from guaranteed cycle times, Cpk and cost per part that meet or exceed their production goals.