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.
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.
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.
We are proud to say that we have not lost a single employee after adding the new robotic systems. Instead of layoffs, employees have been allocated to other parts of the facility,” said the plant manager. “This success has created new business which in turn creates secure jobs. Overall, the addition of the Robotic SUBTA systems has created a more positive and productive environment within our facility. The plastics manufacturer rates the Robotic SUBTA as a great improvement that has been very reliable and nearly flawless in operation.