The plastics manufacturer had used its manual take out system for its entire history for nearly 20 years. This manual system had several pitfalls including a large amount of scrap, which in turn meant money down the drain in throwaway products. The manual system also lacked reliability and increased chances for injuries. The company brought technology into its facility to help increase the production of quality products while making the plant safer for its employees. The company also hoped to increase its sales by improving the manufacturing process efficiencies through automation. Prior to automation, the company had to turn away opportunities to increase its business due to capacity limitations.
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A national manufacturer of stock and custom plastic packaging solutions for the food packaging, chemical, automotive and household industries faced the challenge of improving its safety and ergonomics associated with its manual system of unloading its Nissei Bottle Making Machine at its manufacturing facility. The company also wanted to find a solution to reduce scrap and increase productivity.
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The company contacted Motion Controls Robotics to ask them to help develop a solution that would automate its bottle take out process and alleviate its safety and ergonomic issues due to repetitive stress injuries. They also wanted to create a solution that would reduce scrap, which ultimately would help increase sales without having to produce more product than it did in the past.
Everything in the plant runs much more smoothly. More bottles are being produced, but the pace seems slower since there was a reduction in complexity in the system,” said the plant manager. “We have seen a reduction in the commotion and activity since employees can now work at a constant pace and succeed without as much physical effort. We also have a greater chance to understand the bottlenecks in the manufacturing process. We are reviewing to see where we can make an economic justification for adding automation,” said the plant manager. “We chose the ones that are simple to execute first that run one mold all day, as well as the systems with the highest stress strain or ergonomic safety issues. We are looking for future automation as soon as we can.