Yaskawa Industrial Robots + Automatic Styrofoam Placement?! Korea & Company Battery Palletizing Automation Case Study 🔋🤖

Industry > AutomotiveSector > ManufacturingSector > Logistics

#Battery Palletizing# Palletizing Automation# Industrial# GP250# Marosol# Styrofoam Automatic Loading# Robot Loading System# Smart Factory# Korea & Company

Process Overview

Korea & Company's palletizing solution prioritizes increased production volume and reduced workforce.

After removing the existing line consisting of only one palletizer, we secured production capacity by branching into two lines and configuring two palletizers. We also automated the styrofoam/plywood placement process, which was previously done manually, reducing the need for worker intervention so that one worker manages both lines.

Project Background and Purpose

Background:
The existing work method is structured such that the asymmetry between line production capacity and palletizing capacity requires workers to manually assist with the placement of styrofoam and plywood to meet production quotas. This results in extreme fatigue for workers due to the continuous input of 7kg of plywood, and the Logistics cycle experiences significant fluctuations because workers are forced to wait indefinitely until plywood is manually fed.

Major problems:
- Palletizing quality instability and speed degradation caused by the manual process
- Decline in productivity, increased worker fatigue, skilled worker issue

Objective

Improvement in production efficiency: Minimizing repetitive tasks through the introduction of improved robotic automation
Ensuring quality consistency: Ensuring quality consistency by minimizing manual intervention
Improvement of working environment: Reduction of worker fatigue and enhancement of safety

Components

Robot	BYASAKAWA Industrial GP250
Peripherals	Battery supply inline conveyor, distributor, battery multiple alignment conveyor, dedicated gripper, pallet conveyor, pallet feeder, diverter conveyor, plywood alignment stand, styrofoam supply magazine

Workflow

STEP 1.	Select the battery model and enter the quantity via the HMI
STEP 2.	Align the batteries on the conveyor according to the set quantity and wait for palletizing
STEP 3.	Transfer and secure the batteries to the palletizing position
STEP 4.	The robot aligns the plywood according to the number of layers specified in the recipe
STEP 5.	The 6-axis robot grips multiple batteries simultaneously
STEP 6.	The robot automatically stacks the gripped batteries onto the pallet
STEP 7.	Once a layer is complete, the system automatically seats the styrofoam and plywood
STEP 8.	Repeat the process until the number of layers specified in the recipe is reached

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Features

Productivity Improvement:

30% increase in line production capacity through parallel operation
Securing continuous production capacity using pallets, styrofoam, and plywood as buffers

Ensuring quality consistency:

Ensuring palletizing consistency through standardization of batteries and patterns
Reduced defect rate with breakage prevention design

Improvement of working environment:

Reduced risk of worker fatigue and injury through automation of the worker's performance area
Prevention of musculoskeletal disorders caused by repetitive work

Reduction in operating costs:

Reduction in operating costs relative to increased production capacity by having one person operate two palletizing machines instead of one

Rapid project completion:

Existing line dismantling, setup, and stabilization completed within 5 days of line downtime through prior references and simulations

Results

Client Feedback	The adopting company said, “After setting up the Marosol palletizing line, Logistics flow has become smoother compared to before, and worker satisfaction is high due to a significant reduction in manual labor, and Despite the short setup schedule and concerns regarding the new company's performance, the dismantling and setup were completed in just 5 days. After verifying over 40 varieties without a single instance of failure, stabilization was completed quickly without any disruption to production volume, and the management also spared no praise. "In addition, Marosol's internalization of engineers allowed for immediate responses to variables occurring on-site, making field implementation very easy and resulting in high field satisfaction," they added.

Client Feedback

The adopting company said, “After setting up the Marosol palletizing line, Logistics flow has become smoother compared to before, and worker satisfaction is high due to a significant reduction in manual labor, and Despite the short setup schedule and concerns regarding the new company's performance, the dismantling and setup were completed in just 5 days. After verifying over 40 varieties without a single instance of failure, stabilization was completed quickly without any disruption to production volume, and the management also spared no praise. "In addition, Marosol's internalization of engineers allowed for immediate responses to variables occurring on-site, making field implementation very easy and resulting in high field satisfaction," they added.