Process layout
This application case features an automated stacking solution utilizing the Yaskawa GP180. The system automates the stacking of two different types of products onto their respective pallets. Once a pallet is fully loaded, an operator triggers a switch to signal for forklift transport.
The products retain residual internal heat, making manual handling hazardous. Additionally, with each unit weighing approximately 1.5kg, the repetitive nature of the task caused significant musculoskeletal pain for workers, leading to difficulties in labor recruitment.
Components
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Workflow
| STEP 1. | Alignment: Products are aligned at the infeed section. |
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| STEP 2. | Extraction: The robot extracts the products from the infeed. |
| STEP 3. | Stacking: The robot stacks the products onto their designated pallets according to the product type. |
Features
Thermal-Sensitive Vacuum Handling: Since products retain residual heat, mechanical gripping risks deformation. The system uses optimized vacuum suction for extraction to protect product integrity.
Balanced Load Distribution: The vacuum pad assembly is configured to maintain equilibrium when handling multiple units simultaneously, ensuring precise and stable stacking on the pallets.
Results
| Key Benefits | Reduced Worker Burden: Eliminates the physical strain of stacking high-temperature heavy items.
Labor Shortage Solution: Solves recruitment issues caused by workers avoiding strenuous repetitive tasks.
Manpower Optimization: Transitioned from a 2-person manual operation to a system managed by a single site supervisor.
Improved Work Environment: Reduced individual workloads allow staff to focus on workspace organization, enhancing overall efficiency and morale.
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| Client Feedback | "Our workers previously avoided this task due to the continuous handling of 1.5kg products at 80°C. Since the robot took over, worker satisfaction has increased as the job now only requires simple oversight. Although each person technically manages more processes now, their physical fatigue has drastically decreased, allowing them time to maintain a cleaner and better-organized workspace."
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