Robot Sales Surge in Europe, Asia and the Americas – Are You Part of The Trend?

According to the latest report from the International Federation of Robotics, robot sales in Europe, Asia and the Americas have surged in 2021 (https://ifr.org/ifr-press-releases/news/robot-sales-surge-in-europe-asia-and-the-americas), with a new record of 486,800 units being shipped globally.

Sales in Asia/Australia were the strongest with a 33% increase in installations, Americas increased by 27% and Europe by 15%. At 486,800 robot installations, sales have exceeded the pre-pandemic record of 422,000.

Some of the industries that this robot installations increase has come from are:

  • Food & Beverages +24%
  • Plastics & Chemical +21%
  • Electronics +21%
  • Automotive +37%
  • Metal & Machinery +38%

There are many reasons that manufacturers are turning towards automating processes and installing robots, and with all companies it’s a case of making the decision as to when you will adopt automation rather than whether or not you will.  All companies will eventually have to adopt automation if they want to stay ahead of their competition and remain competitive.

If we turn back in time, there are many industries that simply would not have survived and kept up with the current demand if they had not automated.  One of the key examples of this is car manufacturers. In Spring 2021, VW manufactured around 40,000 cars per day https://www.volkswagen-newsroom.com/en/production-and-locations-3695: a completely unachievable figure if production wasn’t automated! 

These stats all point to the fact that no manufacturing company is exempt from automating their production, and really, it’s just a case of ‘when’ to automate rather than ‘if’.  Some of the key factors that often lead a company to automate include the need to:

  • Overcome labour shortages
  • Boost productivity
  • Improve safety
  • Reduce labour costs
  • Improve product quality
  • Reduce downtime
  • Bring production back in house

Automation can take many different shapes and forms and can be something as simple as picking and placing a product, or it can be as complex as automating the complete manufacturing process of a product from raw material right through to the finished product being put on pallets ready for shipping. 

 

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10 Ways to Motivate Manufacturing Employees

As a manager, one of your many responsibilities is to ensure that your manufacturing staff are engaged and motivated.  Motivated staff will generally work harder and have higher productivity levels, which in turn increases production output and business profitability. Motivated employees are also less likely to be absent from work and staff retention levels will be higher.

However, motivating factory staff that are doing monotonous, repetitive tasks can at times be very difficult. You will also find that what motivates one member of staff won’t motivate another, so you will often need to be creative in the techniques you use, and may have to use different methods for different employees. To help with this, we have created a shortlist of 10 ways in which you can motivate your manufacturing staff.

  1. Lead with Vision

Leading with vision is key to motivating your staff.  If you as a leader don’t lead with vision, your employees are not going to be able to see or fulfil the vision you have.  Having a visual road map for the vision and frequently referring to it will enable your staff to know where they fit in the vision, and enable them to fulfil their part in it.

2. Explain the Why

When you explain the ‘Why’ to your staff, you are likely to get far higher buy-in.  Asking staff to complete a task when they don’t understand the reason behind it will often result in low motivation and disengagement.  Once your employees understand the benefits to themselves and the company, they will be more engaged and motivated.

3. Culture of Recognition and Appreciation

Everyone likes to be recognised and appreciated for what they do, and often it’s the small things that count the most.  Showing staff that you notice and appreciate what they do helps to boost morale and engagement. Simply voicing your appreciation, or saying a simple thank you for something that a staff member has done goes a long way to motivating staff to go the extra mile in completing their day job. 

4. Offer a Clear Path for Advancement

Typically, no one likes to be stuck in a dead-end job.  Showing your staff that there is a clear path for advancement within the company, and working with them to set goals in relation to the career path they’d like to take, helps them to be more engaged and motivated to complete their daily activities.

5. Job Rotation

Job rotation has as twofold benefit.  Rotating staff between different manufacturing roles helps to keep them motivated and reduces the risk of repetitive strain injuries as they’re not doing the same thing every day.  It also provides you with a back up plan if staff are unexpectedly off ill, as you will always have more than one person on site that knows how to fulfil the role.

6. Empowerment

Empowering staff to take responsibility and make decisions themselves will have a very positive impact on their motivation.  This will require training, and they may make some decisions that you don’t agree with, but if they have a clear idea of the company vision and you coach them well, they will soon become indispensable to you. With a shared vision, you will all be working towards the same goal, and there are often many different ways to reach a goal.

7. Training/Professional Development

Well trained staff are likely to perform better and be more engaged as they know what is expected of them in their role and they have been taught the skills that they need to complete the job effectively.  It is also important to encourage continuous professional development in staff as this helps to stretch them and keep them engaged as they move towards new roles within the company.

8. Profit Sharing

Sharing some part of the profits with your staff is a very good way of keeping manufacturing staff engaged.  If they can make an impact on their wage by what they do each day, they are likely to be far more motivated to improve manufacturing techniques and production output as they will see some financial gain from doing so.

9. Performance Related Pay

Performance related pay is a good way of keeping staff motivated.  If they are able to influence how much pay they receive by the tasks they complete, they are far more likely to remain engaged with their work, and to work to the best of their ability. This also enables you as a manager to set standards and targets that are in line with the company vision and goals.

10. Scoreboard/Celebrate Wins

Having an up-to-date scoreboard that your staff can track throughout the day is key to motivating staff.  If staff don’t know whether or not they’re meeting targets they will quickly become disengaged and performance levels may start to lag.  Celebrating wins when they meet a target is also a key part of having a scoreboard as this helps to promote a culture where staff want to meet and exceed targets.  Rewards don’t need to be huge, and can be as simple as a free lunch, or a small gift voucher.

Whilst this list is not exhaustive, these are some of the key methods which can be used to improve employee motivation.  Finding what is right for your manufacturing employees will be a case of trial and error, if you try a technique and it doesn’t work, move on to the next one until you find something that does work.  What works for one member of staff may not work for another, so you will need to be flexible in the techniques you use, and you may have to use a variety of techniques.

You may also find our downloadable resource pack useful as it has some tools that you can use to measure your current output and the improvement in output following the implementation of these techniques.  The pack is downloadable here  https://www.granta-automation.co.uk/freepack and includes an OEE calculator and basic productivity calculator amongst other useful tools.

 

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Why Are Automated Palletisers Becoming More Financially Viable?

With the many social and economic changes that have occurred in the last few years, along with the advances in automation and technology, automated palletising systems are becoming more financially viable than ever before.

In this article we will cover a few of these factors and explain how they have made automated palletising more financially viable for a large number of businesses.

  • Rising Wage Costs
    Rising wage costs, along with the fact that automated technology is becoming cheaper and more commonplace, has had the effect of closing the cost gap between palletising by hand and automating it.  Currently, if you have staff palletising by hand, they are entitled to breaks throughout their shift, and this can mean that production stops during these breaks.  Staff can also be unexpectedly off sick at short notice, which can have the effect of stopping your production process and reducing production output. An automated system will continue to palletise 24/7 and keep your production throughput consistent, quickly improving the payback time of an automated system.

  • Labour Shortages
    Since Brexit, there has been a nationwide labour shortage, which is expected to last until at least 2023 and potentially beyond.  This has also been compounded by Covid, and many manufacturers are finding it increasingly difficult to recruit staff to perform manual jobs within their production processes.   Automating your palletising process gives you the security of knowing that you don’t need to recruit for this area, and staff can be redeployed elsewhere within to company to perform other tasks.  It also gives you the peace of mind, knowing that your palletiser will never phone in sick or have unexpected days off and will be ready to work 24/7.  Depending on the layout of your production, one palletising system will often be able to palletise off multiple lines, and dramatically reduce the head count needed for manual palletising.

  • Advanced Software
    There have been many advances in automated technology over the recent years, and these developments have led to a reduction in the cost of automation.  One of the key areas this has affected in palletising, is the fact that some palletising systems no longer need to be programmed by a skilled robot programmer, they can be programmed by your factory staff instead.  This enables you to palletising different sizes of box or bag off one system, and saves having to pay for a skilled robot programmers time each time you need to set up a new bag or box size.
  • Palletisers That Change With Your Process
    Some palletiser designs have moved away from the traditional style, and have been created to grow with your company; the Granta GA15 palletiser is an example of this. It has been designed as a modular system, that can be added to as your production grows. It can also be easily moved to a different area of your site if your requirements change.  This saves you having to make large capital investments on new palletising systems as your production process change, instead you can simply purchase additional modules for your current system as you require them.
  • Finance Leasing Schemes
    Finance leasing schemes are available and enable you to realise the benefit of automation without having to make a large capital outlay.  To give you an example; over the last few palletising projects we have installed, with a 3 year lease scheme, our customers would make an average production cost saving of £63,063.60 per year after making the lease payments. These savings do not include the value of any production increase, which with a palletiser is typically at least 15%, and more commonly around 40%. They also don’t include any of the other benefits such as; reduced H&S claims, reduced HR, and boosted staff morale. This makes purchasing a palletising system on a finance lease scheme a very attractive option for smaller businesses that don’t have the capital available for an initial outright purchase.
  • Super-deduction Scheme
    The UK Governments Super-deduction scheme is a very attractive tax incentive: for capital expenditure incurred from 1st April 2021 until the end of March 2023, companies can claim 130% capital allowances on qualifying plant and machinery investments.  It allows companies to cut their tax bill by up to 25p for every £1 they invest. This scheme has been created to encourage firms to invest in productivity-enhancing plant and machinery assets that will help them grow, and to encourage them to make those investments now.  Taking advantage of this scheme will effectively enable you to purchase a £100,000 palletising system for as little as £75,300.
  • Payback On Investment
    Typically the payback time on a palletising system is very quick.  This is due to the fact that not only are you saving on staffing costs, but you are also improving the OEE of your process.  Other factors that are often overlooked and affect the payback time include: production throughput increase, reduction in defects/damage, less downtime, reduction in RSI issues.   These two downloadable calculators will enable you to work out the predicted payback time for your process; automation payback calculator and intangible benefits calculator.

As you can see, with the many changes there have been in recent years, along with the current Super-deduction scheme being offered by the UK Government, investing in palletising equipment is a very viable option for most businesses.  For each company it is obviously slightly different, but as a rule of thumb, if you have the equivalent of one person employed full time for palletising, there is payback in less than 2 years.

 

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UK Government Super Deduction Scheme – How Will It Affect My Purchase?

The UK governments Super-deduction scheme is one of the most attractive tax incentives for business investment that has ever been offered by the UK Government.  The scheme has been created to encourage firms to invest in productivity-enhancing plant and machinery assets that will help them grow, and to encourage them to make those investments now.

For capital expenditure incurred from 1st April 2021 until the end of March 2023, companies can claim 130% capital allowances on qualifying plant and machinery investments.  It allows companies to cut their tax bill by up to 25p for every £1 they invest.

Below is a worked example showing what the tax benefit to you would likely be when purchasing a palletising system.

Super-Deduction Scheme Worked Example
  • A company spends £100,000 on qualifying assets
  • Deducts 130% of the initial investment when computing taxable profits which equates to £130,000
  • Deducting £130,000 from taxable profits will save the company up to 19% of that, which equates to £24,700, on its corporation tax bill

Taking advantage of the Governments Super-deduction scheme will effectively enable you to purchase a £100,000 palletising system for as little as £75,300. 

Full details of the scheme are available on the UK government website at https://www.gov.uk/guidance/super-deduction . Please check with your accountants to confirm the extent to which you can benefit from this scheme in your particular circumstances.

If you would like to know more about the Granta GA15 palletising system, feel free to get in touch on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

 

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Can Palletising Be Automated Where The Product Size Changes Frequently?

This is a question that is often asked when automated palletising is being considered. In the past, the answer to this question would have been ‘no’, but with the many advances in technology, multi box, multi line palletising has become possible to automate.  As a result, this has enabled many companies that were not previously able to automate their pallet stacking processes, to now automate, and realise the benefits that automated palletising brings.

Systems have been developed with easy programming software where your staff can input the product dimensions, and then stack patterns are automatically generated.  The video below shows an example of easy programming software on a robotic palletiser.

With the right robotic palletising system, you will be able to program the robot to stack different size boxes off multiple lines simultaneously. This has the added benefit of reducing the amount of capital needed to install a palletising system, as one system can be used for two or more lines.

This video clip below shows a robotic palletiser palletising two different box sizes simultaneously off two production lines onto separate pallets.  This functionality has been made viable by the development of palletising software that can be programmed by factory staff. 

Before purchasing a palletising system it is well worth carrying out research to ensure that the system will meet your requirements.  Some of the key points to ensure you have covered include:

  • Can the system palletise as fast as, or faster than, the speed the production process can run at?
  • Will the gripper head handle the product appropriately without damaging or dropping the product?
  • If you are using slip sheets, can it place them?
  • Can the system be quickly reprogrammed for different bag or box sizes?
  • Can the system be adapted/moved as production processes change?
  • Has your product been tried on the system to ensure it will work?

You may also find this Palletiser URS template useful. https://www.granta-automation.co.uk/news/downloadable-palletiser-urs-template/

If you are unable to make the initial capital payment for purchasing a palletising system, you may wish to consider a leasing scheme.  Purchasing via a leasing scheme enables you to realise the benefits of automating the process without having to make a large, upfront payment for the system. There are various types of leasing options on the market, and more details on the leasing scheme we offer are available here

To discuss your specific application in more detail, feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

 

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Have You Seen This Palletising Video?

This video shows the GA15 palletiser in action! Picking and placing slip sheets and using row gripping to palletise boxes. https://www.youtube.com/watch?v=3dCD_zQc9jk

If you would like to know more, feel free to contact us on 01223 499488 .

 

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Can You Automatically Palletise Open Top Crates or Boxes?

Well, the short answer to this is yes! With the right gripper head, palletising of open top boxes and crates can easily be automated.

Below is a short video showing an underneath gripper palletising open top plastic trays.

As it is not possible to lift open top crates or boxes with a vacuum gripper, an underneath gripper will typically be used. However, bespoke grippers can also be made to lift the product should an underneath gripper not be appropriate. An underneath gripper has tines that slides underneath the open top crate or box, and an arm that goes across the top of the item and clamps down onto it to hold it in place. Once the product has been placed in the desired location on the pallet, the top clamp is released and the gripper tines are withdrawn from under the product.

An underneath gripper also has an integrated vacuum gripper that is used to pick and place pallets onto the conveyor, and also to pick and place slip sheets.

With the GA15 palletising system, stack patterns are automatically optimised in the software, and you can then select the stack pattern that best suits your requirements. The easy programming software also allows your factory staff to reprogram the palletiser for different sizes of crate of box within minutes.

An automated palletiser can also often be used to palletise two types of product off two different production lines.  This helps to minimise capital outlay requirements and helps to keep the floor space requirements to a minimum.

If you would like a budget quote on an automated palletising system, then simply give us a call on 01223 499488 or if you prefer, simply enter your project details into our project builder and we will send you a budget quote.

 

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What Efficiency Increases Do You Get With Automated Palletising?

This is a question that is well worth answering before you commit to investing capital in an automated palletising solution.

Here are some of the efficiency increases that some of our customers have experienced after installation of an automated palletising system:

  • Distribution Centre – automated container unloading and box palletising system installed at a leading supermarket brand. This is saving them a minimum of 119 man hours per week.
  • Chemical Factory – 25kg bag palletising system installed which has resulted in improved efficiencies and improved stack quality, resulting in a reduction in the number of pallets required.
  • Food Factory – palletising system for 25Kg sacks installed which has resulted in an increased production throughput of 150%. It has also reduced labour requirements by 1 person.
  • Refractory Specialist – bag palletising system installed which has resulted in operator requirements being reduced from 2 persons to 1 person. Production throughput is up by 45% and all manual handling elements have been removed.

However, as each application is different, the efficiency increases you may achieve will likely be different to someone else, so we have outlined some of the more common efficiency increases below.

Production Throughput Increase
With an automated palletising system, your palletising process will not have to stop when staff have breaks, fill out paperwork, move goods, etc. Therefore, if your production process is automated and can run without any manual input, your production output will increase with an automated palletising system. Ie, if during an 8 hour shift your production stops for an average of 1 hour due to breaks, forklift movements, etc, your production output will increase by 14% with an automated palletising system.

Improved OEE
In some production processes, the main production line is not able to be run at full capacity as those palletising the product are not able to keep up with these speeds.  An automated palletising system can be designed to pick and palletise layers, or rows of product, onto the pallet to improve the palletising speeds.  This then allows you to run your production process at full capacity and thus increase your output and OEE.

Reduction in Labour Requirements
With an automated palletising system, it is possible for one system to simultaneously palletise different types of product off multiple lines. This can increase you efficiencies dramatically, especially if you currently have more than one member of staff palletising the product off the various lines. Personnel that are no longer required in the palletising department can be redeployed elsewhere within the company.

Reduction In Downtime
With a manual palletising system you always run the risk of downtime due to staff being off sick or on holiday etc. With an automated system this risk is removed, and makes your production process far more predictable and controllable, thus reducing your downtime and increasing your efficiencies. 

Reduction In Defects
Resolving issues related to goods damaged in transit can be costly and time consuming.  An automated palletising system will consistently palletise product to the same standard, and therefore reduce the risk of goods being damaged in transit. This will not only remove the need to spend time sorting damaged goods issues, but will also help with customer retention.

Improved Working Conditions
Automating the palletising process improves working conditions and removes the risk of your workers suffering from repetitive strain injuries. This helps to create a safer working environment for your workers and can improve staff morale as they are redeployed to work in other areas of the company.


These are just some of the efficiency increase that you may experience with an automated palletising system. However, depending on your production process, there will likely be other efficiency increase that you will see as a result of installing an automated palletising system.

To help with giving a value to these predicted efficiency increases, we have created a couple of free downloadable calculators:

You may also find our project builder tool very useful for getting a quick budget quote on an automated palletising system.  https://www.granta-automation.co.uk/project-builder

If you would like to discuss your palletising application, then feel free to get in touch with us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

 

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Small Footprint Palletiser Cell

With space being at a premium in many manufacturing facilities, automated palletising systems have often been unviable in the past due to space constraints. This has meant that goods have had to continue to be palletised manually, along with all the associated manual handling risks.

However, with the introduction of Cobot palletisers, smaller automated palletising systems are now becoming more viable for production facilities with limited space. These systems have their place where you are palletising lightweight products at modest speeds. Typically they will be able to palletise boxes or bags onto two pallet positions, and some, but not all Cobot palletising systems will also be able to handle euro and standard pallet sizes.

Whilst the compactness of a Cobot palletising system allows for automated palletising in areas of limited space, they do still have their constraints. If the system can’t run as fast as your production process can run, then introducing a Cobot palletiser will become a bottleneck to your production throughput. Cobot palletisers are also unable to palletise products when an underneath gripper is required due to the fact that the weight of an underneath gripper is usually more than the weight the Cobot can lift. Also, slipsheets cannot be used with a Cobot palletiser cell as the system is unable to pick and place them.

To meet this need, Granta have developed a small footprint palletising cell that is capable of running at faster speeds and higher payloads. The Granta small footprint robotic palletising cell is typically a KUKA 5 axis palletising robot with 120kg payload. This enables it to palletise higher payloads, and at faster speeds. The cell is customised to suit your requirements, but would usually have two pallet stack positions and an input conveyor. As the cell is modular if allows for flexibility in the layout and shape of the cell, it also enables to you change the modules, or add to the system should your requirements change in the future. This helps to ensure that your investment is future proof as well as meeting your current production and space needs.

With the Granta palletising system a wider variety of products can be palletised as an underneath gripper, bag gripper or vacuum gripper can be specified. This variety of gripper options enables the system to palletise boxes, display boxes, bags, trays, bottles, sacks, drums, open top crates, shrink wrapped items, cans, etc. If a standard gripper design will not work for your product, a bespoke gripper can be manufactured to suit your requirements.

The cell has easy programming software which makes it very simple for anyone to reprogram in minutes. Operators can use the easy-to-use visual software to program the system for different product sizes, pallet sizes and stack patterns. Stack patterns are optimised and you can then choose the stack pattern that suits your requirements. This video shows how quick and easy it is to reprogram the palletiser for different product sizes.

The system can also be used to simultaneously palletise different types of product off multiple production lines. This reduces any capital expenditure requirements, as instead of having to purchase multiple palletising systems, only one system will be required.

One of the best ways to ensure that the robotic palletising system you choose is able to meet your requirements is to trial your product on the proposed solution. This will enable you to see if the system is indeed able to handle your product successfully and at the speeds required. You will also be able to see how neatly the finished pallet is stacked.

We currently offer a free, no obligation palletiser trial service. If you would like to take advantage of this,  Click here to book, or contact us on 01223 499488.

If you would like to discuss your palletising application, then feel free to get in touch with us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

 

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What Are The Benefits Of Robotic Palletising VS Conventional Layer Forming Palletising?

Put simply, robotic palletisers pick and place product from your production line onto a pallet.  Depending on the product and the speeds required, product may be; picked as individual items, as a row of product, or as a complete pallet layer. Whilst robotic palletisers are typically used for stacking pallets, they can also be used to de-palletise product as well.

Robotic palletising systems are able to handle many different types of product such as: bags, boxes, trays, crates, bottles, cans, drums, etc. Depending on the type of product being picked, the robot gripper may be a vacuum gripper, bag gripper, row gripper, underneath gripper, or specialist gripper.

Some of the key benefits of a robotic palletising system versus a conventional layer forming palletising system are outlined below.

Space Saving

A robotic palletising system will typically take up less floor space than a conventional layer forming system as they don’t usually require the large amounts of conveyoring to orientate product that is often needed with a conventional system. One of the smallest robotic palletising systems available on the market is approximately 3 meters x 3 meters. Using a robotic palletising system rather than a conventional layer forming system will therefore free up valuable floor space in your factory that can be utilized for other more beneficial purposes.

Product Flexibility

Robotic palletisers have the ability to be more flexible than a conventional layer forming palletising system as they can be reprogrammed by factory staff to suit different box sizes and stack patterns. The flexibility of a robotic palletiser makes it viable to automate palletising on production lines where a conventional system wouldn’t have been feasible due to regular changes in product sizes and stack pattern requirements. It also gives you the certainty that your palletiser will still work should your product size/shape change in the future.

Flexibility of Layout
Due to the flexibility of robotic palletisers, a robotic palletising system can be installed to suit your current factory layout, whereas a conventional layer forming palletising system is typically a standard layout that you need to alter your production process to suit. Robotic palletising systems can also have different modules added such as automatic pallet dispensing, pallet wrapping, etc., to suit your production speeds and requirements.

Scalability

Scalability is a huge plus point for robotic palletising systems, particularly if you purchase a modular system.  A modular palletising system will only have 4 bolts into the floor for the robot, and the rest of the system will be fixed to this.  This makes the system very moveable and scalable as it is possible to move the system to another area in your factory or a new site, leaving very little residual damage.  This modularity also enables you to add different modules to the system as your production grows, or your requirements change.

Effective Across Multiple Production Lines

A robotic palletising system can be used to simultaneously palletise different types of product off multiple production lines.  This reduces the capital expenditure required, as with a conventional layer forming system, you would need to purchase two palletising systems if you have two production lines with different product types on that you wish to automate.

These are just a few of the benefits of a robotic palletising system vs a conventional layer forming system, and depending on your specific application there are very likely other benefits to take into account.

If you would like more information on the modular Granta GA15 robotic palletising system, then please do get in touch on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.

 

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