Created on 10.10
Operator Training for Warehouse Packing Automation: A Practical Guide
The use of automated systems in warehouse packing can increase efficiency and allow the manufacturer to cope with challenging schedules. But purchasing automated equipment is not everything. The operator has to know how to use the system, ensure its safe operation, and be ready to deal with typical difficulties.
Training must include skills that will be needed by the operator in regular activities on duty and identify which problems he/she can solve independently and which require stopping the machine and turning to maintenance staff.
The following recommendations can be useful in creating a practical training program for warehouse packing automation.
1. Begin by Understanding the General Layout of the System
Prior to running the equipment, operators need to have a good grasp of the components that make up the packing line and how these components work together.
This may include, among others:
- Conveyors and feeding systems for the products
- Sensors and detectors
- Equipment for forming cases
- Robotic case packing equipment
- Grippers and other end-of-arm tools
- HMI
- Safety and emergency stop systems
- Outfeed conveyors
The operator does not have to become an equipment technician. He or she just needs to know the major components of the equipment and how they function.
Having a general idea of how the system works is helpful in spotting abnormal conditions and communicating problems effectively.
2. Training of Operators on Normal Machine Operation
The next step is to have a standardized operating procedure for a normal shift of production.
This should include:
- The approved start-up and shut-down procedures
- Production monitoring
- Routine checks
- Basic control of operations
- This includes knowledge of how to:
- Start up the machine using the approved procedure.
- Check that the line is ready for production.
- Monitor the production process using the HMI.
- Stop the line for any planned change in production.
- Complete the approved shutdown procedure.
With a standard operating procedure in place, it becomes easy to train new operators on the process.
3. Acquire HMI and Recipe Selection Skills
HMI is among the main interfaces that the operator can use to monitor and control an automated packaging line. The training, thus, must incorporate practical HMI lessons and not just theoretical instructions.
The operator must be able to:
- - Read the production screen.
- - Monitor the status and production quantities
- - Identify common alarm messages
- - Find any fault messages
- - Select the right production recipe.
- - Verify that the set parameters correspond to the existing product.
- - Act on the right process when the selected recipe or parameter is wrong
Any change in recipes and parameters should adhere to the procedure set for the specific equipment. The operator should never change the machine parameters except when he/she has permission and is trained.
4. Changeover Training
A changeover is an integral part of automated packaging procedures, especially when the production line has to handle multiple types of products or packaging formats.
It is important for operators to be aware of all necessary steps prior to launching a different production format.
The training may involve:
- Verification of product and case format
- Selection of an appropriate recipe
- Product and case placement verification
- Confirmation of correct gripper/tooling configuration (where applicable)
- Performing a controlled run
- Verification of the right product packing
- Reporting on any abnormal situations encountered
The purpose of this training is not just to perform a changeover quickly but also to perform it consistently and minimize any possible mistakes or downtime.
5. Train in Basic Fault Identification
The operators tend to be the first ones to discover any fault. The training program should hence cover how to identify common faults and react accordingly.
Examples can include:
- Product build-up on conveyor
- Wrong product placement
- Problems in case placement
- Sensor alarms
- Gripper alarms
- Machine stopping unexpectedly
- Recurring packaging faults
Training will teach operators how to interpret the information shown in the alarm, investigate the area safely if required, and use the approved troubleshooting procedures.
No less importantly, it should explain when operators must stop troubleshooting and report the matter to maintenance or technical staff.
Operators should not be allowed to repair any electrical, mechanical, pneumatic, or robotic equipment without proper authorization and training.
6. Incorporate Safety into Every Stage of Training
Safety must not be regarded as a distinct issue in daily operator training programs. Manufacturers can also refer to machinery safety and automation training when developing training procedures for operators working with automated equipment.
It is important that the operators have knowledge of:
- Locations and functions of emergency stops
- Restricted or safeguarded areas within the machinery
- Procedures for safe access
- Approved shut-down procedures
- Actions to take if a person or an object approaches a restricted area
- When maintenance workers should be called
- What tasks need authorized or isolated action?
Emergency training must be practical. Operators may conduct themselves under controlled circumstances to learn the locations of emergency stops and emergency response procedures on-site.
Safety procedures must always be according to the machinery and site requirements.
7. Develop Inspection and Cleaning Routines
The role of the operators in maintaining automated packing equipment in production-ready condition should not be overlooked.
Routine operator inspection includes:
- Removal of product debris from designated areas
- Inspection for contamination near sensors
- Inspecting for damaged parts
- Inspecting conveyors for anything out of the ordinary
- Inspection of guards and safety devices in their usual condition
- Reporting any unusual noises, vibrations, and frequent alarms
The goal of this routine is to detect problems early on rather than to substitute for regular maintenance carried out by qualified people.
Developing a shift checklist will ensure that these routine inspections are done properly.
8. Train Operators to Record Production Data Accurately
While automation systems will be able to provide useful production and fault data, operators must learn to interpret this data and record the important events.
Training may include:
- Count of productions
- Quantities of product/cases
- Downtime events
- Number of alarms
- Changeover times
- Packing mistakes
- Rejected products/cases
- Maintenance/technical issues
Keeping accurate records will allow the supervisor to see if any recurring problems exist and if the problem is due to the machine, product, material, or process.
If there are multiple products/batches run at one facility, the operator will also need to know the labeling needs of that facility.
9. Checklists and Practice Exercises
It becomes simpler to administer training if there are checklists and training exercises for the operators.
Training need not just be from the manuals but can include:
- Short class lectures
- Demonstrations of equipment
- HMI practice
- Changeover exercises
- Practice fault detection
- Safety drills
- Shift checklists
- Production practice
The operators must show proficiency in performing tasks before being allowed to do them independently.
There should also be record-keeping of the training sessions so that it is easy to know which part of the training has been attended by whom.
10. Define Escalation Procedures
One of the key things that an operator should learn during his/her training is how to avoid intervening where he/she should not.
The escalation procedure should include the following:
- Which alarms the operator is able to fix
- Which alarms require the presence of maintenance personnel?
- When the production process should be halted
- Whom to call depending on the type of alarm
- What data must be noted prior to escalating the issue?
An operator might be able to remove the approved obstruction of the product from the machinery according to its procedure. Recurring mechanical, electrical, and robotic control issues will require intervention of the qualified technical staff.
11. Make Training Relevant and Up-to-Date
Training does not end once the system has been set up. For manufacturers using robotic packaging and end-of-line automation solutions, operator training should also be reviewed when the equipment, packaging process, or production requirements change.
Further training is needed when:
- New products or pack formats are launched
- The packing process changes
- New machinery is set up
- New software functions are employed
- Operating mistakes become recurrent
- Changes occur in safety protocols
- New operators are added to the production line team
Checking training and production records periodically can assist manufacturers in identifying areas requiring further training.
Conclusion
Automation of packing in warehouses is most effective when operators have an understanding of the equipment used, as well as of their duties in the process of automation. It is important to note that adequate training is not associated with the necessity for each operator to be a robotics engineer or a technician. What is needed is to provide operators with the information they need to use the equipment reliably, identify faults, and act accordingly.
Training should include information about basic principles of the equipment’s functioning, correct usage, changeover procedures, fault identification, safety considerations, equipment checks, production reports, and fault escalations.
Such a combination of procedures and training can contribute to the reliable performance of automated packing systems.
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