Process Overview
Hankook & Company’s palletizing solution prioritizes higher output and reduced labor requirements. After removing the existing line that was built around a single palletizer, the operation was split into two lines and reconfigured with two palletizers to secure production capacity (CAPA). In addition, manual placement of styrofoam and slip sheets was automated to reduce operator intervention—enabling one operator to manage both lines.
Project Background and Objectives
Background
The previous workflow had an imbalance between line production capacity (CAPA) and palletizing capacity (CAPA), requiring operators to manually support styrofoam and slip-sheet placement to maintain output. This structure forced continuous loading of slip sheets (approx. 7 kg each), causing significant operator fatigue. Also, the line had to wait until manual slip-sheet loading was completed, leading to large fluctuations in the logistics cycle time.
Key issues
Palletizing quality instability and speed loss caused by manual operations
Reduced productivity, increased operator fatigue, and skilled-labor dependency issues
Objectives
Improve production efficiency by minimizing repetitive manual tasks through upgraded robot automation
Ensure quality consistency by reducing manual intervention
Improve the work environment by reducing operator fatigue and strengthening safety
Components
| Robot | YASKAWA industrial robot GP250 |
|---|---|
| Peripherals | Battery infeed conveyor Sorter Battery bundle alignment conveyor Dedicated gripper Pallet conveyor Pallet supply unit Diverter conveyor Slip-sheet alignment station Styrofoam supply magazine |
Workflow
| STEP 1. | On the HMI, select the battery model and enter the required quantity. |
|---|---|
| STEP 2. | Batteries fed from the infeed line are aligned on the conveyor to the required count and queued for palletizing. |
| STEP 3. | The load is transferred and fixed in position at the palletizing station. |
| STEP 4. | Based on the recipe total layer count, slip sheets are aligned accordingly. |
| STEP 5. | The 6-axis robot grips the battery bundle. |
| STEP 6. | The robot automatically loads the bundle onto the pallet. |
β» The content provided by Bigwave Robotics is protected under U.S. and Canadian copyright and intellectual property laws. Unauthorized reproduction, distribution, or use of this content is strictly prohibited.
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Process Overview
Hankook & Company’s palletizing solution prioritizes higher output and reduced labor requirements. After removing the existing line that was built around a single palletizer, the operation was split into two lines and reconfigured with two palletizers to secure production capacity (CAPA). In addition, manual placement of styrofoam and slip sheets was automated to reduce operator intervention—enabling one operator to manage both lines.
Project Background and Objectives
Background
The previous workflow had an imbalance between line production capacity (CAPA) and palletizing capacity (CAPA), requiring operators to manually support styrofoam and slip-sheet placement to maintain output. This structure forced continuous loading of slip sheets (approx. 7 kg each), causing significant operator fatigue. Also, the line had to wait until manual slip-sheet loading was completed, leading to large fluctuations in the logistics cycle time.
Key issues
Palletizing quality instability and speed loss caused by manual operations
Reduced productivity, increased operator fatigue, and skilled-labor dependency issues
Objectives
Improve production efficiency by minimizing repetitive manual tasks through upgraded robot automation
Ensure quality consistency by reducing manual intervention
Improve the work environment by reducing operator fatigue and strengthening safety
Components
| Robot | YASKAWA industrial robot GP250 |
|---|---|
| Peripherals | Battery infeed conveyor Sorter Battery bundle alignment conveyor Dedicated gripper Pallet conveyor Pallet supply unit Diverter conveyor Slip-sheet alignment station Styrofoam supply magazine |
Workflow
| STEP 1. | On the HMI, select the battery model and enter the required quantity. |
|---|---|
| STEP 2. | Batteries fed from the infeed line are aligned on the conveyor to the required count and queued for palletizing. |
| STEP 3. | The load is transferred and fixed in position at the palletizing station. |
| STEP 4. | Based on the recipe total layer count, slip sheets are aligned accordingly. |
| STEP 5. | The 6-axis robot grips the battery bundle. |
| STEP 6. | The robot automatically loads the bundle onto the pallet. |
β» The content provided by Bigwave Robotics is protected under U.S. and Canadian copyright and intellectual property laws. Unauthorized reproduction, distribution, or use of this content is strictly prohibited.
Related Use Cases
Yaskawa Industrial Robots + Automatic Styrofoam Placement?! Korea & Company Battery Palletizing Automation Case Study ππ€
Smart Machine Tool Assistant "G-AiD" using Collaborative Robots