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Losing 5 to 7 Years of Robot Life: Analyzing the Wear in the FANUC M-410

Robot Disassembly & Assessment

The following case study involved GMP (Good Manufacturing Process) customer that utilizes a Fanuc M-410 robot together with a PASCO vacuum EOAT to palletize cases. The cell features a 3 in, 2 out configuration with a shuttle car feeding a stretch wrapper.

This customer runs the robot at nearly full capacity at 100% speed using the full range of motion available. The robot is in operation 24/7, 365. The PM intervals were originally set, by the customer (Based on the OEM basic recommendations), to every three years.

001. // The Challenge

As you will see below, this resulted in three of the four axes being damaged. The cost of the repairs was estimated to be in the range of $80,000. While the basic recommended PM interval is every 3 years or 11,520 hours, operating conditions, range of motion utilized, speed and other factors should be taken into account when setting PM intervals.

002. // The Solution

In this particular application, the PM should have been scheduled to occur annually. The estimated PM cost of $6,400 a year could have saved the extensive repair cost along with saving downtime of 3-4 days. Follow along below to see the damage caused by not taking into account all operational variables when setting PM schedules.

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003. // Conclusion

This robot was deemed to be ‘beyond reasonable repair’, and was replaced with a
brand new FANUC M-410 within two days by the PASCO service team.

With annual preventative maintenance properly executed this robot could have provided another 5 to 7 years of dependable service.

Financial Comparison

Robot Replacement

ROBOT COST

$97,000

INSTALL & STARTUP

$31,000

TOTAL

$128,000

PM Service Plan

ANNUAL COST

$6,000

NUMBER OF YEARS

9

TOTAL

$54,000

John Hopson

PASCO SERVICE MANAGER

Provides the first response to customer needs for parts, service, and operational support. Recruits, trains, and retains top talent for the service team. Manages, schedules, and executes installs, startups, and service work to be performed.

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