New approaches from OMRON for more efficiency in High-Mix, Low-Volume (HMLV) packaging

Five challenges in packaging and palletizing processes and how they can be overcome with the help of smart robotics solutions.

Robot-assisted automation solutions offer support

Smart robot-based automation solutions can help overcome the need for manual labour that arises in High-Mix, Low-Volume (HMLV) production. Such solutions include robotic picking, packing, palletizing, machine tending, and optimized automated intralogistics..

Challenge 1: Mixing products in secondary packaging

Mixing different single products in a display carton presents challenges. To handle and improve the flow of goods, a solution combines a complete range of different robotic automation technologies, for example, into a single, fully integrated packaging system that offers built-in algorithms that allow the different production lines to be coordinated and flow rates to be optimized. 

For users, this means greater flexibility, fewer machine idle times, a reduction in the workload for employees, and lower costs and complexity in the (re)packaging line.

Challenge 2: Material replenishment on the line

It makes sense to improve line-side replenishment (LSR) while avoiding the need for operators to perform repetitive tasks. Finally, automating the supply of consumables minimizes intermediate storage of consumables and waste in the re-packing area.

Cobots, perhaps combined with mobile robots, can remedy this situation by assisting with material feeding. Such collaborative robotic solutions can improve throughput while allowing employees to focus on value-added tasks. Examples include selective compliance assembly robot arms (SCARA) tasked with loading bottles or other containers, or high-speed parallel robot solutions used to align and position items 

Challenge 3: Intralogistics and intermediate storage

Innovative robotic solutions can help here to optimize the throughput and availability of required goods. Material transport and shipments can be handled by autonomous mobile robots. 

The advantages of automated material transport are obvious: automatic replenishment ensures reduced inventories, space optimization, and just-in-time procurement. At the same time, waste can be minimized, and safety strengthened. Pallets are no longer needed along the line and waiting times are eliminated. Added to this is the traceability and control of stock, while the movement of small-batch inventory (WIP) is automated.

OMRON robot solutions are based on traditional stationary robots, collaborative robots (cobots), autonomous mobile robots (AMR), or the MoMa (mobile manipulator). For the AMRs OMRON Fleet Simulator additionally offers the industry’s first mobile robot simulator for factory and manufacturing applications. It plans traffic and workflows for fleets of autonomous mobile robots, allowing users to identify potential bottlenecks early and optimize workflows without having to deploy a real robot at all.

Challenge 4: Unpacking and distributing goods

Distribution centres or repacking sites must deal with other challenges, including depalletizing and unpacking cartons, transporting goods to be repacked, but also disposing of waste. In addition, there is a steady increase in SKUs and a shortage of skilled labour, which further complicates the tasks. Fully or semi-automated handling and robotic transport can save a lot of effort here. 

AMRs can operate as part of a fleet that drives autonomously and executes orders based on a picking system. 

Challenge 5: End-of-line palletizing

Palletizing is not a suitable task for human workers. Innovative EOL palletizing solutions provide support here. Cobots significantly simplify palletizing. Palletizing with collaborative robots helps users quickly set up their palletizing specifications. Compared to industrial robots, such a solution requires 50% less floor space. A safety fence or cage is not required, and operators can safely work side-by-side with the robot, enabling continuous operation. Operators can easily remove an entire pallet without stopping the cobot.

Conclusion

Modern automation and robotics solutions help make co-packing and packaging operations fit for the factory of the future by enabling a perfect balance between productivity and ease of use. Solutions are available that are scalable both upward and downward to handle swinging demands from supply chain, reduce total cost by reducing topics as floor space required or intermediate stock.