TIDI Merchandise, a world producer of an infection prevention and affected person security merchandise, remodeled its end-of-line operations by automating with Lean Palletizing. The outcome: measurable beneficial properties in productiveness, safer working circumstances, and extra environment friendly use of labor.
This case exhibits how robotic palletizing can straight enhance manufacturing efficiency with clear, repeatable outcomes.
Key outcomes at a look
- 30% improve in palletizing productiveness (first cell)
- 25% extra productiveness beneficial properties (subsequent cells)
- 2× efficiency enchancment by combining work cells
- Decreased labor from two operators to at least one per cell
- Important discount in pressure and harm danger
The issue: handbook palletizing restricted manufacturing capability
Earlier than automation, palletizing at TIDI Merchandise was totally handbook. Operators dealt with a number of duties, together with:
- Constructing bins
- Filling and sealing them
- Transporting and stacking them on pallets
This created two important bottlenecks:
Labor inefficiency
One operator usually needed to handle a number of stations, decreasing focus and throughput.
Manufacturing delays and misplaced income
Backlogs elevated, and the corporate was pressured to say no orders.
Not solely was handbook palletizing sluggish, it prevented the corporate from scaling.
The answer: Robotiq Lean Palletizing
TIDI Merchandise deployed Robotiq palletizing options to automate repetitive and bodily demanding duties on the finish of the road.
The system supplied:
- Constant palletizing efficiency
- Flexibility throughout product traces
- Quick operator adoption resulting from ease of use
This allowed the crew to rapidly transfer from handbook dealing with to a scalable, automated course of.
Outcome 1: 30% productiveness improve within the first deployment
The primary palletizing cell delivered a 30% improve in productiveness.
This rapid achieve got here from:
- Eliminating handbook dealing with time
- Decreasing operator motion between stations
- Growing total line velocity
For producers evaluating ROI, this exhibits how a single automation venture can rapidly unlock capability.
Outcome 2: Repeatable beneficial properties throughout a number of cells
After the preliminary success, extra palletizing cells have been deployed.
Every new cell delivered:
- 25% productiveness enhancements on common
This demonstrates an necessary precept of automation: as soon as a course of is standardized, enhancements develop into repeatable and scalable.
Outcome 3: Doubling output by redesigning the workflow
Automation enabled TIDI Merchandise to rethink its manufacturing structure.
By combining two workstations into one:
- Output per cell doubled
- Operator necessities dropped from two to at least one
- Uptime elevated throughout operations
It is a key perception: robotic palletizing doesn’t simply automate duties; it permits course of redesign for increased throughput.
Outcome 4: decreasing labor constraints whereas growing effectivity
Labor challenges have been a serious driver for automation.
After deployment:
- One operator can now handle a number of processes
- Employees deal with higher-value duties like machine operation
- General effectivity improves with out growing headcount
This helps producers preserve output even in tight labor markets.
Outcome 5: enhancing employee security and ergonomics
Guide palletizing required repetitive lifting of bins weighing as much as 25 lbs (11kg).
This led to:
- Strains and sprains
- Fatigue and misplaced workdays
With robotic palletizing:
- Damage dangers have been considerably lowered or eradicated
- Bodily pressure on employees decreased
- Jobs turned much less bodily demanding
Bettering ergonomics additionally helps long-term workforce retention.
Outcome 6: constant output and improved product high quality
Guide palletizing required coaching and nonetheless launched variability.
Automation delivered:
- Constant pallet patterns
- Decreased coaching time
- Extra dependable output
This results in higher product high quality and improved buyer satisfaction.
Why this issues for producers contemplating palletizing automation
This case highlights how robotic palletizing improves:
- Manufacturing throughput
- Labor effectivity
- Office security
- Operational consistency
Most significantly, the outcomes are measurable and repeatable.
Conclusion: a quick, scalable path to increased efficiency
TIDI Merchandise achieved:
- 30% productiveness beneficial properties instantly
- Continued enhancements with every new deployment
- Safer, extra environment friendly operations
Their recommendation is straightforward: Automate sooner to unlock outcomes quicker.
For producers coping with labor shortages, manufacturing bottlenecks, or security issues, palletizing automation gives a transparent path to enchancment.
Discover out if palletizing automation is best for you
Undecided in case your software is an efficient match for Lean Palletizing?
Use our Palletizing Match Instrument to rapidly consider your palletizing wants and see if automation can ship comparable ends in your operation.
