Challenge:
A major manufacturing plant of a food and beverage brand based in India was facing challenges in managing a large workforce of factory workers doing mundane and repetitive tasks of picking and placing goods in a box, packaging corrugated boxes, and taping boxes for a number of different SKUs of different sizes on different production lines. Any incorrect handling of the goods or incorrect labeling led to severe consequences in the brand image, and positioning in the market including huge public outcry on social media. The manufacturer wanted to reduce its workforce on such mundane and automatable tasks without making any massive changes to its production line keeping all automation within the constraints of its current processes
Implementation of Special Purpose Robotics Machines:
Step 1
Our specialist team visited the site and had a walk through the manufacturing plant and a detailed understanding of the problem and challenges and the reason for each.
Step 2
We divided the problem relating to each of the lines into packing, taping, packaging, printing, and inspection. We then designed a custom solution for each of these problems.
Step 3
We used a mix of robotic arms, sensors, linear motors, integrated control systems, and PLCs to solve each of these problems separately and then prepare to be tested in the real environment within the given constraints of temperature, vibrations, and other stresses.
Step 4
Once tested and the machine setup successfully passes the evaluation criterion for one of the production lines, these systems are deployed into each of the production lines to start automatically doing packaging, packing, and taping. The system is monitored for quality and accuracy for a period of 2-3 weeks for any minor adjustments.
Note that the solution doesn’t aim to replace humans 100% from the cycle but helps them automate mundane and repetitive tasks that earlier required multiple workers allowing them to move to better work and conditions.
Benefits:
- Increased Efficiency: The system inspected parts at a much faster rate than human inspectors, allowing clients to increase their production rate.
- Enhanced Accuracy: The system drastically reduced the margin of error in inspections. It detected defects that were often missed in manual inspections.
- Cost Reduction: Though the initial setup was capital-intensive, the system paid off in the long run. Savings were made by reducing the number of defective parts and returns, and by optimizing the production process using the collected data.
- Improved Reputation: Consistently delivering high-quality components bolstered the client’s reputation, leading to increased orders and expanding clientele.
To read about Manufacturing Process Optimization using Machine Learning, visit our case study on Manufacturing Process Optimization using Machine Learning
At Levintutu, you will discover a variety of solutions meticulously crafted to meet the needs of diverse industries. From precision-guided robotics that optimize your manufacturing processes to data analytics that unveil hidden patterns, we offer services designed to increase your efficiency and redefine your success: https://levintutu.com/robotics/
Conclusion:
The adoption of these special-purpose robotic machines suite serves as a compelling testament to the benefits of technology integration in India’s manufacturing sector. Not only did it reduce the workforce, but it also enhanced quality and production efficiency to further maximize the return of the manufacturing process.
Tech@Levintutu is the technical team at @Levintutu who writes on the latest technology and its applications in industrial automation. To read more about us, visit our blogs at https://levintutu.com/blog/.
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