Robot Case Study - Factory Shipping Department

The case study presented here is a prime example of the deployment of a basic industrial robot added to the production line of a typical factory setting. The cost savings are significant when compared to the acquisition and operational costs of the new robot. Additional savings are the result of the productivity increase gained by the redeployment of labor resources.

The Setting: The factory in this case is the producer of processed foods, specifically pickled products like peppers, pickles, and even sauerkraut. The product is packaged into glass jars, then placed into a cardboard carton. At the end of the assembly line process, the packed boxes of product travel down a conveyer belt where they are then placed onto a wood pallet. The pallet is then moved to a storage location pending shipment.

The Problem : The point where the packed boxes need to be placed onto the pallet from the conveyer belt is the step in the manufacturing process that has been identified as the problem. When production levels increase, it is at this stage where a bottleneck will occur, thus limiting the entire rate of production. Addianaly, this work is considered to be the most undesirable in the entire facility, as it is back breaking labor.

The Solution: After careful analysis, it was decided that the installation of a robot would be the most appropriate solution to this problem. A purpose built 'Pallettizing' robotic arm and controller system was acquired. It was essentially purchased of the shelf, meaning that this is a proven platform and application. It was not custom designed and built like many systems found in factory settings.

The robot arm lifts each cardboard box of jars from the conveyer belt and places them on the wooden pallet in the proper location. Each box precisely placed every single time. The machine can operate at a speed commensurate with about three times the current maximum operating speed of the factory. Considering the fact that the facility currently only operates a single manufacturing shift each day, this machine--capable of operating twenty four hours per day--will probably never need to be replaced as the production levels may increase.

The Savings: Work that was done by three or four people is now done by a machine. Because of the nature of the work, employees would take turns. These employees were highly skilled factory workers that were useful at other areas in the facility. The robot has made it possible for this valuable labor to be re-deployed. The total number of jobs have been reduced, and through attrition, the actual number of paid employees.

Because of the previous bottleneck, overall factory operation was limited to a fixed level, a level that was not sufficient to meet customer demands at peak times throughout the year in this business where demand it seasonal. The implementation of the robotic Aron has eliminated this bottleneck, allowing the factory to be able to ramp up production levels to the extent necessary.

As the business grows, the single robot will be able to keep up with any level of production that may be needed in the future.

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Written by: Owen R. Matthews