Are you ready for the Christmas rush? These compact palletising systems can be leased for as little as £3.96 per hour! They start as small as a Smart car and are available in time for Christmas.
Improving throughput during peak production periods is crucial for maintaining efficiency, meeting customer demand, and maximising profitability. This often requires a strategic blend of process optimisation, automated technology, workforce management, and effective coordination. Here are some simple strategies that can be implemented to enhance throughput:
Process Optimisation
Streamline Workflows:
Identify and Eliminate Bottlenecks: Conduct a thorough analysis of your production processes to pinpoint bottlenecks. Implement solutions to alleviate these constraints and smooth the flow of operations.
Standardise Procedures: Develop and enforce standardised operating procedures (SOPs) to ensure consistency and efficiency across all production stages. SOPs help in reducing variability and increasing reliability.
Lean Manufacturing:
Minimise Waste: Adopt lean manufacturing principles to eliminate waste in all forms; whether it’s excess inventory, unnecessary movement, or inefficient processes.
Just-In-Time Production: Implement just-in-time (JIT) production techniques to reduce inventory costs and enhance responsiveness to customer demand. This approach ensures that materials arrive only when needed, reducing storage requirements.
Kaizen and Continuous Improvement:
Foster a culture of continuous improvement (Kaizen) where employees are encouraged to suggest and implement small, incremental changes. These small changes accumulate to significant improvements over time.
Workforce Management
Cross-Training Employees:
Enhance Flexibility: Cross-train employees to perform multiple roles, increasing the flexibility of your workforce. This allows for quick reallocation of labour to where it is most needed during peak periods.
Incentive Programs:
Motivate Performance: Implement incentive programs that reward employees for high performance and efficiency. Recognition and rewards can drive employees to maintain peak productivity.
Flexible Scheduling:
Adapt to Demand: Utilise flexible work schedules to ensure that labour is available during peak demand times. This might include staggered shifts, part-time work, or overtime as necessary.
Technology and Automation
Automation
Reduce Human Error and Increase Speed: Implement automation in repetitive and time-consuming tasks. Automated systems can operate continuously with high precision, reducing errors and increasing throughput.
Automated Palletising: Integrate automated palletising systems to handle the stacking and organising of products onto pallets. This reduces manual labour, speeds up the packaging process, and ensures consistent pallet quality.
Advanced Manufacturing Technologies:
Utilise Cutting-Edge Tools: Where possible, invest in advanced manufacturing technologies such as 3D printing, robotics, and CNC machines. These tools can significantly enhance production speed and accuracy.
ERP Systems:
Integrate Operations: Deploy Enterprise Resource Planning (ERP) systems to integrate production planning, scheduling, and inventory management. An ERP system provides real-time data and analytics, facilitating better decision-making.
Supply Chain and Inventory Management
Supply Chain Optimisation:
Ensure Timely Deliveries: Improve coordination with suppliers to ensure timely delivery of raw materials and components. Establish strong supplier relationships to secure priority during high-demand periods.
Resilient Supply Chains: Develop a resilient supply chain that can quickly adapt to changes in demand and supply conditions.
Inventory Management:
Smart Techniques: Implement inventory management techniques like ABC analysis to prioritise high-value items. Use methods such as safety stock and buffer inventory to handle unexpected spikes in demand without disrupting production.
Facility and Equipment Management
Preventive Maintenance:
Avoid Downtime: Schedule regular preventive maintenance to prevent unexpected equipment failures. Well-maintained machinery operates more efficiently and reduces downtime during critical periods.
Capacity Expansion:
Increase Production Capacity: Consider temporary or permanent capacity expansion by adding additional shifts, purchasing new machinery, or outsourcing parts of the production process.
Data and Analytics
Real-Time Monitoring:
Quick Issue Resolution: Implement real-time monitoring systems to track key production metrics. This enables quick identification and resolution of issues, minimising disruption.
Data Analytics:
Predictive Insights: Leverage data analytics to accurately forecast demand and plan production schedules. Data-driven insights can optimise resource allocation and improve overall efficiency.
Quality Control
Enhanced Quality Control:
First-Time Right: Implement stringent quality control measures to ensure products meet quality standards on the first pass. Reducing rework and defects directly improves throughput.
Communication and Coordination
Effective Communication:
Keep Everyone Aligned: Improve communication channels within the production team and across departments. Clear and efficient communication ensures everyone is informed and aligned with production goals.
Integrated Planning:
Collaborative Approach: Coordinate planning efforts across departments such as sales, marketing, and production. Integrated planning ensures that production aligns with market demand and organisational goals.
By implementing some, or all of these comprehensive strategies, you can significantly enhance throughput during peak production periods. This leads to better operational efficiency, reduced costs, and improved customer satisfaction, ultimately driving higher profitability and competitive advantage. Automated palletising, in particular, can be a game-changer by reducing manual labour, increasing speed, and ensuring consistency in product handling, further boosting overall throughput.
When using an automated palletising system, keeping production running during pallet changeovers is often essential for high-speed production lines. Here are some specific strategies that can be implemented to achieve continuous production with an automated palletising system:
Dual or Multiple Pallet Stations
Implementation: Equip the automated palletising system with dual or multiple pallet stations. This setup allows one station to be actively palletised while another is prepared or having its full pallet removed. This ensures that when one station pauses for changeover, the other can seamlessly take over without interrupting the production flow.
Examples: Safety systems like light curtains or shuttling gates or other safety interlocks can be integrated to allow the robot to palletise on one pallet position whilst a pallet is being loaded or removed from the other position.
Automated Pallet Dispensers with Pallet Conveyors
Implementation: Integrate automated pallet dispensers that can supply empty pallets to the palletiser and automated conveyor systems to transport pallets through to the palletiser and on to a safe zone after the pallet is stacked. These systems reduce the need for manual intervention, significantly speeding up the changeover process between pallets.
Example: An automated dispenser can hold a stack of empty pallets and a conveyor can feed them into the palletiser as needed. Once the pallet is stacked a conveyor system carries full pallets to an area where they can be removed from the conveyor without causing the system to stop palletising.
Buffer Systems
Implementation: Install buffer conveyors or accumulation before the palletising system on the product infeed to the system. These systems temporarily hold products during pallet changeovers, allowing the production line to continue running without interruption.
Example: A buffer product infeed conveyor with a holding capacity of several minutes’ worth of production can maintain the flow of products from the production line while a pallet changeover is in process. A buffering conveyor for full pallets will also allow the system to hold a certain number of full pallets that are waiting for removed without stopping they system from palletising.
Automated Guided Vehicles (AGVs) or Autonomous Mobile Robots (AMRs)
Implementation: Deploy Automated Guided Vehicles (AGVs) or Autonomous Mobile Robots (AMRs) to transport full pallets away from the palletising station and bring empty pallets to it. AGVs/AMRs can operate continuously as they can enter the palletiser safety zone whilst the robot is running, ensuring that pallets are always available for the palletiser.
Example: AGVs/AMRs that navigate the production floor, picking up full pallets from the palletiser and delivering them to the warehouse while simultaneously bringing empty pallets to the palletising area and the robot never has to stop during the pallet changeover as the AGV/AMR does not break the safety of the system.
As you can see, there are various different methods that can be implemented to ensure that production remains continuous during pallet change overs. The method best suited to your production will depend on your production speeds, product being palletised etc. If you would like to discuss your specific application, please contact us on 01223 499488 .
Typically, an underneath gripper would be used to palletise products that cannot be easily picked with vacuum from the top of the products, for example open-top trays, boxes with perforated lids, bottles etc. However an underneath gripper can be used for almost any application including standard tape top and bottom boxes. As nearly any product can be stacked with an underneath gripper, it works well for applications where there are mixed products needing to be palletised with the same palletiser. The video below shows an underneath griper palletising boxes and open top trays.
How an Underneath Gripper Handles Mixed Products
Integration with Production Line
Sensor-Based Detection:
As items come off the production line, sensors detect their type, size, and shape. This information is crucial for the gripper to adjust its configuration accordingly.
Dynamic Adjustment:
The gripper dynamically adjusts its forks or support platform based on the detected item. For boxes, it ensures a stable lift from underneath, and for open-top trays, it carefully supports the base to prevent any disturbance to the contents.
Smooth Transition:
The transition from lifting a box to lifting a tray is seamless. The system’s control software coordinates the movements of the gripper to switch modes efficiently without interrupting the flow of the production line.
Benefits of Using an Underneath Gripper in Mixed Production Lines
Versatility and Flexibility:
One of the primary advantages is the ability to handle different types of items without needing multiple grippers. This versatility reduces equipment costs and minimises the complexity of the automation setup.
Space Efficiency:
Using a single gripper system for both boxes and trays saves space on the production floor. There is no need for separate handling areas or additional machinery, allowing for a more compact and efficient production environment.
Reduced Downtime:
The adaptability of the gripper reduces the need for manual adjustments or changeovers between different types of items, leading to less downtime and higher overall productivity.
Improved Safety and Handling:
The underneath support provides a stable lifting method that minimises the risk of dropping or damaging items. This is particularly important for open-top trays that may contain delicate or loose contents.
Consistent Palletising:
The gripper ensures consistent placement of items on the pallet, maintaining uniformity and stability in the pallet stacks. This consistency is crucial for efficient storage and transportation.
Practical Considerations
System Design and Implementation
Customisable Configuration:
The gripper can be customised to handle specific dimensions and weights of boxes and trays commonly found on the production line. This customisation ensures optimal performance and reliability.
Integration with Existing Systems:
The underneath gripper can be integrated with existing conveyor and packaging systems, providing a streamlined addition to the current production setup.
Maintenance and Support:
Regular maintenance and calibration of the gripper and its sensors ensure continued precision and efficiency. Support from the manufacturer can provide ongoing improvements and troubleshooting as needed.
Conclusion
An underneath gripper provides an effective solution for palletising mixed items such as boxes and open-top trays coming off the same production line. By ensuring stable and gentle handling of diverse items, the underneath gripper helps maintain the integrity of products while optimising the palletising process. This integration leads to increased productivity, reduced operational costs, and a smoother workflow on the production floor.
If you would like to know more about mixed product palletising, please contact us on 01223 499488 .
Yes, a single robot can effectively palletise products from multiple production lines onto multiple pallet locations – watch the video below.
This capability can significantly enhance operational efficiency and flexibility in manufacturing settings. Here’s how it can be accomplished:
How It Works:
Advanced Programming: The robot is equipped with sophisticated programming that enables it to recognise products from different lines and understand where each product needs to be placed. This involves mapping out the exact positions of incoming products and their designated pallet location.
Integrated Conveyor System: Multiple conveyor belts are used to transport products from various production lines to a central pick-up area. This setup ensures that the robot can access products from all lines without needing to move extensively.
Vision Systems and Sensors: The robot employs advanced vision systems and sensors to identify and differentiate products. These systems help the robot determine the size, shape, and type of each product, ensuring accurate and efficient handling.
Gripper design: The robot’s gripper is designed to suit the variety of product types that need to be handled, such as boxes and trays. To maintain efficiency, the gripper will typically be designed to enable it to lift all of the different product types required, as gripper change overs during the palletising process reduce cycle time and efficiency.
Practical Steps:
Conveyor Design: The conveyor system is designed to converge products from different lines into a central location that the robot can easily access. This reduces the need for multiple robots and simplifies the overall layout.
Strategic Robot Positioning: The robot is then placed in a central position where it can reach both the convergence point of the conveyor belts and the palletising area efficiently. This strategic placement minimises the robot’s movement and maximises its productivity.
Safety Measures: Safety measures such as sensors, barriers, and emergency stops are integrated into the system to ensure safe operation. These measures protect workers and equipment, creating a safe working environment.
Example Workflow:
Product Convergence: Products from different production lines are transported via conveyor belts to a central pick-up area.
Product Identification: The robot uses its vision systems and sensors to identify each product and determine which line it came from and where it needs to be placed.
Pick-and-Place Operation: The robot automatically calculates motion paths using AI, and palletises according to lane priority. Efficiently picking and placing products one by one, or in multiples.
Benefits:
Increased Efficiency: By handling multiple lines with a single robot, the system reduces the need for multiple palletising setups, thereby streamlining operations and saving valuable floor space.
Cost Savings: Utilising one robot instead of multiple robots and associated equipment significantly cuts down on capital expenditures and operational costs.
Enhanced Flexibility: The system can easily adapt to changes in production lines and product types, providing a versatile solution that can handle a wide range of palletising tasks.
For more information, or to discuss you specific applications, contact us on 01223 499488 .
Understanding the differences between modular, compact, and cobot palletisers is essential to enable you to select the right system for your specific needs. Here’s a brief summary of each type of palletiser system and their pros and cons:
Structure: Composed of multiple interchangeable modules, which can be configured and reconfigured to suit different layouts and applications.
Flexibility: Highly adaptable to changing production needs or product types.
Scalability: Can be easily expanded or modified to accommodate increased production capacity or new product lines. Allowing you to future proof your investment.
Ease of Use: Available with easy programming software that is designed for easy programming and operation by operators without extensive technical expertise.
Best For:
Operations that require high flexibility and scalability.
Industries with frequent changes in product types or packaging configurations.
Businesses planning for future growth and needing the ability to upgrade their palletising system.
High speed and/or heavy product requirements.
Pros:
Customisable to specific needs.
Scalable and upgradable.
Can handle a wide variety of products.
Quick to install and reconfigure due to the modularity of the system.
Cons:
Sometimes requires more floor space.
You can’t easily get pallet truck take off combined with automatic pallet feed.
Structure: Designed to occupy minimal floor space whilst utilising an industrial robot. All necessary components integrated within the small footprint. This system also has automatic pallet feed through it, with low level pallet truck take off.
Application: Typically used in space-constrained environments. Or where pallet truck take of is required.
Integration: Incorporates all functions, such as infeed conveyors and pallet handling, into a single compact unit.
Ease of Use: Available with easy programming software that is designed for easy programming and operation by operators without extensive technical expertise.
Best For:
Facilities with limited floor space.
Industries with frequent changes in product types or packaging configurations.
Applications where pallet truck take off is required in combination with high production speeds.
High speed and/or heavy product requirements.
Pros:
Space-saving design.
Typically lower cost than larger, more complex systems.
Quick to install.
Cons:
Less flexible and scalable in the future compared to modular systems.
Structure: Utilises collaborative robots (cobots) designed to work alongside human operators without the need for extensive safety guarding.
Flexibility: Highly adaptable and programmable for different palletising tasks.
Ease of Use: Designed for easy programming and operation, even by operators without extensive technical expertise.
Best For:
Operations where human-robot collaboration can enhance productivity.
Applications requiring frequent changeovers and varied product types.
Application where space is limited.
Pros:
Safe to operate alongside humans.
Flexible and easily reprogrammable.
Lower upfront cost compared to larger automated systems.
Cons:
Some systems can be slower than the larger palletising systems.
Limited payload capacity compared to traditional industrial robots.
The choice between modular, compact, and cobot palletisers depends on your specific operational needs:
Modular Palletisers: Choose for high-speed production, and future flexibility and scalability.
Compact Palletisers: Choose for high-speed production, space efficiency and pallet truck take off.
Cobot Palletisers: Choose for collaborative work environments, low cost and space efficiency.
The best type of palletising system for your application will depend on your production volume, space availability, and the need for flexibility. If you are unsure which type of system would be best suited to your application, we would be more than happy to advise. Simply contact us on 01223 499488 or contact us at helpline@granta-automation.co.uk. We will be very happy to help.
The Granta cobot palletiser system is one of the smallest palletising systems available. So small, it’s virtually the same size as a Smart car and fits into the smallest of spaces.
Don’t get caught out this Christmas! Get your’s ordered now for installation before the Christmas rush…
AGVs (Automated Guided Vehicles) and AMRs (Autonomous Mobile Robots) are both utilised for material handling and transportation within industrial and warehouse settings, but they differ in design, capabilities, and operational behaviour.
AGVs:
Guidance and Operation: AGVs are typically guided by physical systems installed on the floor, such as magnetic tape, wires, markers, or some of the most advanced systems use laser measuring systems. They follow predetermined paths or routes, often with fixed endpoints. AGVs are well-suited for repetitive tasks along fixed routes and are ideal for environments with well-defined pathways. They rely on collision avoidance systems to stop (or take a different pre-programmed route if available) when encountering obstacles, ensuring predictable behaviour and safe operation.
Benefits: AGVs offer efficiency and predictability in operations, ensuring consistent material handling. They generally require lower initial investment costs compared to AMRs due to their simpler navigation systems. AGVs are suitable for environments with stable layouts where repetitive tasks are prevalent.
Watch an AGV in operation…
AMRs:
Guidance and Operation: AMRs are typically equipped with laser sensors or other sensing systems and onboard intelligence that enable them to navigate autonomously without the need for physical guidance systems. They can dynamically adapt to changes in their environment and navigate around obstacles in their path automatically. AMRs are more flexible and versatile than AGVs, capable of handling complex tasks and environments. They continuously operate, navigating around obstacles while maintaining workflow efficiency.
Benefits: AMRs offer flexibility and scalability, adapting to changing environments and tasks without requiring significant modifications. They enhance workplace safety by autonomously navigating around obstacles and avoiding collisions. AMRs are suitable for dynamic workplaces where layouts may change frequently or where tasks require adaptability and agility.
Watch an AMR in operation…
Choosing Between AGVs and AMRs:
Predictable vs. Adaptive: AGVs offer predictability and efficiency in repetitive tasks along fixed routes, while AMRs provide adaptability and versatility in dynamic environments with changing layouts.
Cost and Complexity: AGVs may have lower initial investment costs but require infrastructure modifications for guidance, whereas AMRs offer greater flexibility and scalability without the need for extensive infrastructure changes.
Safety and Continuous Operation: AGVs rely on collision avoidance systems to stop or reroute to a different pre-programmed path when obstacles are detected, ensuring safety and predictable behaviour. AMRs autonomously navigate around obstacles, maintaining continuous operation and workflow efficiency. Some companies prefer AGV’s in terms of safety as people know exactly where they will run and there is less chance of coming head-to-head with one in an unexpected location.
Speed of operation: AMRs advanced navigation software can significantly improve the speed of operation by navigating around obstacles rather than stopping in dynamic environments, however an AGV system on pre-defined predictable routes that are kept clear can be very fast and efficient and give more speed. With both systems, as operators and those working in the area get used to the paths they take and keep the routes clear they increase in speed and efficiency.
In reality the line between an AMR and AGV is getting blurred with advances in technology and it is advisable to look at the technology of each available system and see how well it is suited to your specific application. Some examples of crossovers between AGV and AMR technology are as follows:
Some AGV technology has advanced laser measurement systems that dynamically map where they are, similar to AMR’s, and although they follow a pre-defined route, they will also use sensors to adapt their route e.g. for block stacking products.
Some AMR technology has pre-set paths available in the software and the AMR can be set to run just like an AGV on a set path only.
Consideration of these factors, aligned with specific operational needs and long-term goals, can guide the decision-making process when choosing between AGVs and AMRs for material handling applications. If you do not have prior experience with both AMR’s and AGV’s it’s advisable to get a specialist automation company who offers both technologies to come and look at your application and give you a technical recommendation for which technology is best suited to your requirements.
If you would like to know more about AGVs and AMRs, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk. We will be very happy to help.
A cobot palletiser is a type of robotic palletising system that utilises collaborative robots (cobots) to stack boxes, cartons, or other items onto pallets.
Unlike traditional industrial robots, cobots are designed to work alongside humans in a shared workspace, and can safety work alongside humans without any additional safety or barriers being required. However, they do run slightly slower in collaborative mode to meet all the safety requirements. With additional safety such as guarding or scanners, some cobots will switch to industrial robot speeds until the safety is broken by a person entering the safety zone, when it will then slow to collaborative robot speeds. This enables the system to continue to palletise product whilst full pallets are being removed from the cell.
This type of palletising system is particularly useful in environments where flexibility and adaptability are required, as cobots can be easily reprogrammed to handle different products or palletising patterns. A cobot palletiser is also often used where there is limited space available as it typically has a very small footprint.
If you would like to know more about the Granta Cobot Palletiser, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk. We will also be very happy to arrange a free demonstration at our site.
Many companies are currently affected by labour shortages, which is in turn affecting their production capabilities. To address labour shortages in production effectively, there are a wide variety of strategies that can be used, and below is a list of some of the more common strategies;
Competitive Compensation and Benefits: Ensure that your compensation packages are competitive within the industry to attract and retain skilled workers. Consider offering bonuses, profit-sharing, retirement plans, healthcare benefits, and other perks to enhance employee satisfaction.
Recruitment from Non-traditional Sources: Expand your recruitment efforts to target non-traditional sources of talent, such as retirees, veterans, individuals with disabilities, or stay-at-home parents re-entering the workforce. Consider partnering with community organizations and vocational schools to tap into these talent pools.
Automation and Technology Integration: Implement automation and technology solutions to augment human labour and increase productivity. This can involve robotics, AI-driven systems, machine learning algorithms, and IoT devices to streamline production processes and reduce reliance on manual labour. Two key automation solutions that typically have a very fast payback are palletiser and AMRs/AGVs, both of which can be purchased on finance schemes.
Implement Lean Manufacturing Practices: Streamline production processes and eliminate inefficiencies through the implementation of lean manufacturing principles. By optimizing workflows and reducing waste, you can maximize the productivity of your existing workforce.
Outsourcing and Contract Labour: Consider outsourcing certain tasks or projects to external contractors or temporary labour agencies to supplement your workforce during peak demand periods. This can provide flexibility without the long-term commitment of hiring full-time employees.
Cross-Training and Multiskilling: Cross-train employees in multiple roles or departments to enhance flexibility and adaptability within the workforce. This can help mitigate the impact of absences or turnover by ensuring that employees can fill in for one another as needed.
Whilst there is no quick fix to labour shortages in production, by automating processes that can be automated you can minimise your dependence on manual labour and ultimately reduce the impact of labour shortages on your production processes. Also, cross training your staff for the jobs that do require manual labour helps to minimise disruption during periods of labour shortage.
If you would like to discuss any palletising or AMR/AGV applications, then feel free to contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to help.
