Robotic Case Packer

Problem

Staff shortages, a small footprint, and quick changeover requirements were limiting the client’s throughput and up-time capabilities.

As production facilities know, throughput and efficiency is key to running an effective business. Due to footprint, and employee constraints, Sharpe’s client was not packing finished goods up to their full capacity. The small case types also posed a challenge to erect and manage, as well as consistently achieving quality control standards for label presence, correctness, straightness, orientation, and legibility.

Solution

An automated system, utilizing robotics and custom equipment, was designed and integrated by Sharpe. 

To achieve maximum versatility, Sharpe specified and purchased a Fanuc CRX25i, complete with a tool-less end-of-arm tool, flip-up guide rails, small-radius transfers and custom fill-plates, and a custom designed case erector to accommodate the abnormal small cases.

Results

A 30% increase in line rate, and an estimated payback period of less than 1.5 years.

Overworked staff were moved and trained in higher value areas of the facility, and the system solution was fit, with multiple access points, within a 100 square foot area. Changeovers were quick and effective, completed in around one minute utilizing the tool-less feature of the Fanuc robot, with the flip-up guardrails ensuring accuracy every time when changing from product to product. The case-packer was the most challenging portion of the project- when put into production as manufactured it was unable to meet production demands. As the system’s integrator, Sharpe stepped up and provided modifications to the unit, working with the respective vendors to provide a high performing, reliable and safe alternative to meet throughput requirements.