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Case Study on Reliability of Automotive Painting Shop Robots

Robots in automotive assembly plant are crucial for automation of the plant. As the robots are expensive, they are the main contributor to plant investment. Thus, it is important for the robots to have high reliability. This paper presents the reliability analysis of robots at an automotive assembly plant. The analysis was based on operating hours and frequency of the failures of the robots. The data were acquired from plant maintenance data. Using seven years of failure data, the robots’ mean time between failures (MTBF) and reliability were evaluated. Constant failure rate was assumed in the analysis. From the analysis it is noted that the reliability of the robots at the plant varies from 15% to 62% and 2% to 39% for 10,000 hours and 20,000 hours respectively. These findings could assist the maintenance manager to schedule the maintenance and replacement of the robot at the plant.