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The plastics manufacturer also considered a vendor with a fixed automation system that included a simple slide but decided that system wasn’t reliable enough for its needs. In addition, every time the mold tooling changed, the slide also had to be changed to accommodate the new product. This created a higher cost to change tooling that was not acceptable. The facility included one machine with a manufacturers fixed automation system, but they wanted to find a more flexible and reliable solution.
Motion Controls Robotics’ created the Robotic SUBTA system, a pre-engineered robotic system designed for PET blow-molded bottle handling. The system uses different robotic units depending on the type of machine that is being unloaded. The Robotic SUBTA system grabs and sets the bottles on a conveyor, standing up, acting as a takeaway unit. The system provides increased throughput due to high reliability and uptime and cycle times faster than most mold machine rates. The Robotic SUBTA system also requires a minimum of floor space, a high priced commodity in a manufacturing facility.

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The Motion Controls Robotic SUBTA has received a positive reception from the employees because of the ease of use and nearly flawless performance of these robots. To ward off any concerns from employees about potential layoffs within the plant, the company presented the new system as an opportunity to ramp up its technology and that new business was waiting for the company if the technology was added.

The Robotic SUBTA systems have also created unexpected improvements in the manufacturing process. The company noted a net reduction of 1/2 percent of scrap, adding 500,000 bottles per year to its output simply by virtue of not dropping the bottles. Since fewer products need to be reground, the company also saves money considering the cost to run the regrind machines has gone up greatly as the cost of oil increases. In addition, this reliable process has cut the employee bending movements by 50 percent.
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