The plastics manufacturer also considered a vendor with a fixed automation system that included a simple slide but decided that system wasnâ€™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.
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 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.
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.