Created on 09.07
Optimizing Robotic Palletizing Systems for Peak Performance
There are many cases where factory floors cannot produce goods consistently because manual palletizing is the point of inconsistency. At times of peak activity, a shortage of personnel can exacerbate the issue. Robotic palletizing can help companies dealing with such issues achieve better consistency in performing repetitive activities at the end of the production line.
Nevertheless, a mere installation of the robotic system does not guarantee that it will be able to perform effectively in the production environment. To be efficient, a robotic system should operate in coordination with conveyors, packaging machines, and sensors. The present article explains how manufacturers can recognize bottlenecks and improve robotic systems.
Problem: Throughput Bottlenecks
Throughput bottlenecks commonly occur when products start piling up at the end of the production line. Machines used for filling, packaging, or case packing will still operate, but the manual palletizer cannot keep up.
In such cases, the bottleneck does not have to do with the speed of one machine. The real issue may have something to do with lack of coordination among various processes in the production system.
Manual palletizing will also bring about inconsistency in product stacking.
Inconsistent Stack Geometry
Inconsistent stacks could occur due to inconsistent product stacking. If the positioning of cases and bags varies, it may cause unbalanced pallet loads.
The lack of proper stack geometry could cause difficulties in both storage and transport. Inconsistently stacked products might need additional handling, which in turn causes a higher possibility of product damage.
Using a robotic palletizer, products could be placed on pallets following a pattern programmed in the machine.
Limitations to Throughput Capacity
Manual palletizing systems have a limited capacity. As the upstream equipment speeds up, manual operators find it difficult to keep up the pace for the entire shift period.
Thus, there will be a difference in production capacity and end-of-line handling capacity, causing upstream equipment to be slowed down or even stopped.
Finding this bottleneck process is crucial before implementing automation.
Why It Happens: What Causes End-of-Line Problems
The inefficiency at the end of the line is typically due to several related reasons, not just one issue.
Two examples include a mismatch between packaging machinery and palletizing machinery, and inflexibility of machinery as product specifications evolve.
Mismatch Between Machines
If machinery operates in a stand-alone mode, the material flow will be inconsistent.
In the case of the packaging line, the machinery may deliver products at a faster rate than the palletizing cell can handle them. With no adequate capacity for buffering and information exchange, there will be accumulation and subsequent jamming of products.
A good end-of-line automation solution has to synchronize conveyors, sensors, case packing equipment, robotic palletizers, and control systems.
Rigid Mechanisms
Another issue is associated with the inability of older machinery to work with new product specifications.
With any change in products requiring many adjustments to machinery, changeover times will increase.
Flexible tooling and palletizing patterns allow for modification of the production line without changing hardware every time.
The Solution: Intelligent Automation in Practice
In case of production problems in palletizing through manual means, automation may be seen as an effective solution.
Apart from automation for automation’s sake, the manufacturer needs to look at the entire process and how it fits into the overall manufacturing processes.
For any manufacturer planning on investing in robotic palletizers, Techflowbot has automation solutions tailor-made for various production needs. The International Federation of Robotics (IFR) also provides industry information on the use and development of robotics in manufacturing.
The process of implementing intelligent automation involves three basic steps:
- Assessment of current production processes.
- Selection and configuration of appropriate robotic equipment.
- Integration of robotic equipment within the production environment.
Step 1: Conducting Throughput Analysis
Before deciding on equipment purchase, assess the existing production flow.
Note the current flow rate and find out at which point the products start piling up. Evaluate the speed of the conveyor belt, case packaging rate, and palletizing capability.
This should give you an idea if palletizing really is the bottleneck in your production flow or if it is some other stage.
Throughput analysis will help you find areas for improvement within your flow regardless of well-functioning equipment.
Step 2: Implementation of Multi-functional Robotic System
After the identification of the bottleneck process, the second step involves the selection of a suitable robot and tooling system based on the application.
Some key factors that need to be considered in this respect are:
- Product weight
- Product size
- Type of packaging
- Production rate requirement
- Dimensions of the pallet
- Stacking pattern
- Floor space availability
- Change-over requirements
Tooling system for the robot is another key aspect, as different types of products may necessitate vacuum or mechanical gripper systems, or even custom-designed tooling.
Step 3: Implementing Centralized Control
Palletizing robots are not designed to operate alone.
Centralized control enables the robot to work in concert with conveyors, sensors, packaging machinery, and other machinery in the assembly line.
The system can respond accordingly if the products start to accumulate on the upstream conveyor or the downstream conveyor comes to a halt.
Effective communication among the machinery can make it easier to troubleshoot and isolate any problems that occur in the production line.
Manual vs. Robotic Palletizing Systems
In assessing automation, manufacturers should consider the whole production process instead of basing their decisions on one number.
Feature | Manual Process | Robotic Solution |
Throughput | Limited by operator capacity and working conditions | Designed for consistent automated flow |
Placement | Can vary with fatigue and handling conditions | Programmed and repeatable |
Changeover | Depends on manual adjustments and product requirements | Can be simplified through programming and suitable tooling |
Repetitive Handling | Requires continuous manual lifting and movement | Automates repetitive palletizing tasks |
Production Stability | More sensitive to labor availability | More consistent during scheduled operation |
Scalability | Often requires additional labor as volume increases | Can support future expansion with suitable system design |
Prevention of Repetition: Keeping the System Stable
The automation process must not be viewed as a system that can be implemented and then run without any ongoing maintenance.
Periodic system maintenance is helpful for maintaining robotic palletizing systems to operate consistently and avoid any unexpected interruptions.
Sensor Calibration on a Regular Basis
Sensors are significant for product detection and system synchronization.
Factors such as dust, product deposits, and surrounding conditions can negatively impact sensors' performance. Inspecting and cleaning sensors can assist in avoiding such effects.
In the case of vision systems, manufacturers also need to perform calibration and maintenance as recommended by equipment manufacturers.
Firmware and Software Maintenance
Robotics controllers and other relevant software should be maintained periodically as recommended by manufacturers.
Software updates can lead to better performance and stability, better motion control and diagnostics, as well as compatibility with other equipment.
However, software updates must always be tested in accordance with manufacturers' recommendations before implementation into the working process.
Predictive Maintenance
Current robots have the ability to give valuable information about their operating status.
Maintenance staff can check various parameters, like operating cycles, fault history, motor conditions, and so on, to detect possible problems.
This way, maintenance will be planned according to the production schedule and won’t depend on unpredictable equipment failures.
When To Get Some Help: Expertise for Complicated Automation Projects
Not every production line can be automated by using standard packages only.
Sometimes, companies’ teams lack the necessary resources to handle the integration process, especially when multiple devices, complicated layouts, or special handling are needed.
In this case, cooperation with an experienced integrator will minimize the risks of implementation.
You can contact Techflowbot to discuss product specifications, available floor space, interfacing equipment, and production requirements when developing an automation solution.
Manufacturers can consult our engineering department for getting the professional assessment of their end-of-line automation needs.
Managing Multi-product Complexity
For products with different dimensions or packaging styles, a different handling mechanism or palletizing pattern might be needed.
As such, the automation process needs to take into consideration all of the products, rather than optimizing itself for a particular SKU.
Using appropriate fixtures and programmable settings would simplify the process of managing multiple products in the same production area.
Space Considerations
Space availability is another factor to consider.
A palletizing cell should be large enough to accommodate a robot, a few pallets, conveyor systems, safety mechanisms, and other related items.
Considering all of these components during the planning stage would enable manufacturers to maximize the use of the available floor space.
Growth Through Scaling
The production needs of the organization can vary over time.
The company can develop new products, produce in larger volumes, or even include more packaging varieties. Thus, automation must be planned as an integral element of the production strategy.
Taking into account future needs from the very beginning of the system development can facilitate future scaling.
Conclusion: Accuracy Brings Growth
It should not be thought that the end-of-line performance accuracy is contingent only upon the robot’s speed.
In order to make sure that everything runs well, one has to consider all aspects of production, such as conveyors, packaging systems, product handling, tooling, controls, maintenance, and future production requirements.
Robotic palletizing systems can be useful to make the end-of-line operation more consistent. Yet, each company has its own products and production goals and its own production setup, which means that the solution must be selected based on the specifics of a certain production site.
The best way to do it is to find out where exactly the problem is and to solve it by choosing the appropriate automation.
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