The importance of packaging robots in the manufacturing industry?

Introduce

The importance of packaging robots in the manufacturing industry

Packaging robots bring speed, precision and productivity to material handling operations, which has a real and lasting impact on overall manufacturing operations. Most manufacturers that deploy packaging robots see a significant increase in throughput because production speeds are not hindered by the speed of packaging, moving and/or labeling products of manual processes.

Furthermore, packaging robots help streamline the production process. They can lift more products at once, have much higher uptime than manual labor, and help reduce labor costs. Packaging robots can complete more packaging tasks at a lower cost and more consistently than manual labor.

Packaging robots are becoming a staple in many applications, from the medical field to industrial manufacturing, they are bringing core benefits to manufacturers.

Topic overview

Considerations for investing in packaging robots. The advantages and limitations that this solution brings. Factors for successful implementation and production of packaging processes.

 

Learn about Packaging Robots

Definition and role of packaging robots

Robotic packaging is the use of automated machinery and robots to perform packaging tasks, typically in an industrial setting.

Robotic packaging systems enable a range of different packaging tasks, such as picking, placing and palletizing, to be performed safely, efficiently and effectively. Robotic packaging equipment can consist of stand-alone robots, including the popular robotic arm that can be used for pick and place, or they can be integrated into broader manufacturing processes, such as on automobile assembly line.

Packaging robots deliver many important benefits in applications across industries. When compared to manual processes, packaging robots deliver the speed, precision and productivity that robotic automation is known for, while also delivering a relatively fast return on investment (ROI). when implemented correctly.

Industrial robotics is a diverse and complex technology – even within the category of packaging robots, different systems can accomplish very different tasks.

Types of packaging robots and their applications

There are many different types of automatic assembly and packaging machines, suitable for each production requirement:

• Transmission type automatic assembly machine: uses a conveyor system to transport products throughout the assembly process.
• Rotating type automatic assembly machine: uses a turntable to move products to assembly stations.
• Flexible assembly machine: can assemble many different products thanks to the system that automatically adjusts parameters.
• Robotic assembly machines: use industrial robots to replace labor in assembly.
• Automatic packaging machine: performs the packaging and product packaging process after assembly.

Benefits of using packaging robots in the production process

Packaging machines bring many benefits to manufacturing businesses:

• Increase labor productivity 5-10 times compared to manual work.
• Minimize errors during assembly.
• Ensure high accuracy and stability for the product.
• Save labor, reduce production costs.
• Can work continuously for long periods of time without needing to rest.
• Easily change assembly stages for new products.
• Minimize labor safety risks.

Key factors to consider before investing

Cost Analysis: Initial Investment and Long-Term ROI

ROI can be used to evaluate various metrics, all of which help determine how profitable a business is. To calculate ROI with the highest accuracy, it is necessary to measure total profits and total costs.

When calculating a positive ROI, this means that the business — or the ROI being measured — is profitable. Meanwhile, if the calculation has a negative ROI percentage, it means the business — or the metric the business is being measured against — owes more money than it earns. In short, if the percentage is positive then the profit will exceed the total cost. If the percentage is negative, the investment will be at a loss.

For example, if a company wants to invest in a new computer deployment, it must consider a variety of deployment costs. Businesses need to consider the actual price of the computer, taxes and shipping costs, consulting or support fees payable at purchase, plus setup and maintenance costs.

The business will then need to calculate its net profit over a certain period of time. These net profits can include hard dollars that come from increased productivity and reduced maintenance costs compared to previous computers.

That business can then calculate ROI when evaluating two different types of computers using predicted costs and expected profits to determine which ROI is higher. So which calculator represents a better investment: Investment A or Investment B?

Requires automation for the packaging process

Packaging processes can be automated to optimize efficiency, reduce errors and save time. Here are some automation requirements for the packaging process:

• Automatic Packaging Machine System
• Automatic Measurement and Testing System
• Automated Material Management System
• Production Management Software
• Automation Integration
• Automated Traffic System
• Automated Monitoring and Reporting System

Compatibility with existing machinery and infrastructure

Depending on existing equipment as well as current production level, a reasonable investment can recover capital after the shortest period of time.

Flexible and customizable options

Some robots are integrated with many technologies that can be used in many different industries and production processes. However, some robots can only be used in certain pre-designed occupations or jobs.

Consider safety and regulatory compliance

Robots almost always ensure safety and compliance with production regulations.

 

Evaluate suitable packaging robot solutions

Analyze production volume and output requirements

Production Volume

• Determine the total amount of product that needs to be packaged in a given time period (e.g. hourly, daily, or weekly production).
• Analyze production time allocation during the working day.

Production Speed

Assess the complexity of the packaging task

• If there are many types of products to be packaged, the robot needs to be able to adapt flexibly.
• Packaging tasks are too complex, so choose advanced robots or robots capable of working with humans.

Consider the type of product being packaged

The type of product that needs to be packaged is important in choosing the right machine. Each machine has a certain capacity and load capacity, making it unsuitable for many types of products.

Identify required functions and features

If the packaging job is simple, you should choose machines with simple structures that both ensure production speed and the fastest capital recovery.

Choose the right packaging robot supplier

Research and review reputable suppliers

Contact and learn about large, reputable suppliers. Meets all criteria for robots as well as customer care.

Evaluate the supplier’s track record and experience with packaging robots

Some suppliers have many years of experience. They can advise and recommend the most optimal and effective production processes.

Review customer feedback and testimonials

Referencing customers who have used the service before is also a way to refer to the effectiveness and reputation that the company brings.

Evaluate the supplier’s after-sales support and maintenance services

Large companies often have 24/7 maintenance systems, but some small companies cannot meet this requirement. Therefore, choose a supplier with a maintenance system to help the production process recover and be able to operate again quickly.

 

Installation and deployment process

Understand the installation process and logistics: Understand the requirements of the system or application to be installed, including software and hardware if necessary. Make sure the system is running enough software and hardware to support the new application. Perform software installation according to vendor specific instructions or customize if necessary.

Ensure staff training and knowledge transfer: provide training for new users and prepare documentation.

Develop a comprehensive implementation plan:

• Determine goals and requirements
• Risk analysis
• Identify people with expertise to do it
• Make a detailed schedule
• Determine installation principles
• Divide specific tasks
• Plan testing and training

Monitor and optimize packaging robot performance

Establish performance metrics and key performance indicators (KPIs)

Set appropriate indicators for the packaging process such as:

• Packaging speed
• Packaging accuracy
• Stop time
• OEE performance
• Number of products packaged in shifts
• Capacity efficiency
• Cancellation rate
• Preparation time

Regular maintenance and calibration procedures

Monitor system performance and troubleshoot problems

Continuously improve processes and optimize output

• Invest and update new processes and software optimized for robots.
• Improve each product’s process for the highest speed and best accuracy

 

Potential challenges and mitigation strategies

Identify potential challenges in implementing packaging robots

Implementing packaging robots brings many benefits in terms of speed, efficiency and accuracy in the packaging process. However, there are also potential challenges that need to be identified and resolved to ensure project success. Here are some potential challenges when implementing packaging robots:

• Product versatility: Robots are often programmed to perform a specific task. If there are changes in the size or shape of the packaged product, the robot may need to be adjusted or reprogrammed to accommodate these changes.
• Interact with diverse environments: Production environments can vary depending on the product line or manufacturing process. Robots need to handle effectively a variety of environmental conditions, from temperature to humidity and other factors.
• Labor safety and interaction with humans: Packaging robots often operate in close proximity to humans. This poses a challenge in labor safety, requiring safety measures to avoid collisions and ensure safe interaction between robots and workers.
• Investment and deployment costs: Deploying packaging robots sometimes requires a large investment from businesses. This cost includes not only the cost of purchasing the robot, but also the cost of employee training, system implementation, and maintenance.
• Employee training and skills: Adjusting the workforce to work effectively with robots requires new skills training. This can be difficult depending on the employee’s acceptance and ability to learn.

Develop strategies to overcome challenges and minimize risks

Risk assessment:

• Identify all the risk factors that could affect your project or business plan.
• Prioritize risks based on impact and likelihood of occurrence.

Risk classification:

• Categorize risks into categories such as business, technical, human resources, organizational culture, and others.
• Understand the causes and consequences of each type of risk.

Develop a risk mitigation plan:

• Develop risk mitigation measures for each identified risk type.
• Set specific goals and limit risks to a minimum.

Develop a recovery plan:

• Prepare a treatment plan for each risk, in case they occur.
• Determine the resources needed to implement this plan.

Case studies and success stories

Highlighting the successful deployment of packaging robots

ABB:

• ABB is one of the leading companies in the field of automation and industrial robotics.
• ABB robots are often integrated into packaging systems to enhance performance and ensure accurate packaging.

CRY:

• KUKA is also a famous industrial robot supplier.
• This company has successfully deployed packaging robots to improve productivity and packaging quality.

Fanuc:

• Fanuc is one of the leading companies in industrial robotics and automation.
• Fanuc robots are often used in packaging processes to optimize production.

 

Present the benefits and results achieved

Increased Productivity: Packaging robots can work continuously without breaks, thereby increasing production productivity compared to manual labor.

• Packaging Quality: Using robots helps ensure accuracy and uniformity in the packaging process, reducing the risk of human errors and keeping products of high quality.
• Save Labor Costs: Automating the packaging process reduces dependence on labor, thereby reducing personnel-related costs.
• Flexible and Customizable: Robotic systems can easily be adapted to meet special packaging needs and have the flexibility to switch between different products.
• Safety and Energy Efficiency: New technology enhances safety and reduces energy consumption during robot operation.

These companies have proven that using robots in the packaging process not only brings high efficiency but also brings many different benefits to businesses.  

Conclude

Summary of key considerations for successfully deploying packaging robots

Implementing a successful robotic packaging system requires careful consideration and preparation. Here are some important considerations to ensure a smooth implementation:

Analyze needs and goals:

• Clearly define the goals and needs of the business.
• Make sure that implementing packaging robots will help improve performance and reduce costs.
• Choose a suitable robot:
• Choose a robot that suits the specific requirements of the packaging process.
• Make sure the robot can integrate easily into the existing system.
• Analysis of the packaging process:
• Understand current packaging processes to optimize robot integration.
• Ensure that the robot can adapt to fluctuations and special requirements in the process.

Personnel training:

Quality control:

Labor safety:

• Comply with occupational safety rules for using robots in production environments.
• Provide safety and protection measures for employees working near robots.

Integrating IoT and AI:

• Use IoT technology to collect data about robot performance and status.
• Consider integrating artificial intelligence to improve automation and error management.

Encourage making informed investment decisions in packaging

Investing in packaging and packaging brings many benefits to businesses such as:

• Product protection
• Convenient access to customers
• Distinguishing brands
• Environmental protection
• Increasing productivity
• Create quick awareness