THE PROBLEM
Packaging at the end of a processing line was labor intensive and could lead to quality issues especially with new operators. Parts could vary from 500mm up to 3000mm long coming off of two different machines.
THE PD&B SOLUTION
PD&B worked directly with the customer to determine the solution for both lines and what each one would look like while also creating contingency plans if certain parts had to be switched from one line to another. This solution required the end customer to accept some changes in the way their product was packaged and shipped, but with the labor cost savings and quality improvements, the ROI was favorable to the automation implementation.
The main component of this equipment is the Fanuc industrial robot that utilizes Dual Check Safety control paired with a multitude of floor scanners and light curtains to maintain an extremely safe operational environment while also allowing the equipment to continue working in areas while operators are interacting with others. PD&B integrated this cell with the upstream equipment’s PLC to create a seamless solution. Due to the wide range of part bundle lengths, easily swappable tooling was utilized. Simple fastener secured tooling vs a fully automated tool changer was selected because of cost/benefit analysis – tools were only swapped out maybe once a week or so, not during every shift or cycle. On the shorter part system, we elected to create a dual station packaging system so that while an operator is loading or unloading a full/empty tote, the equipment could continue running, maximizing efficiency and uptime.