Process layout
Process Overview
Philliper had been handling the process of inserting nuts into the machine tool manually. Due to the repetitive nature of the work and insufficient precision, this led to reduced productivity and quality issues. To resolve this, they implemented an automation solution using four Hyundai robots and two Doosan robots.
Project Background and Objectives
Background
Philliper was experiencing work inefficiency and inconsistent quality in the existing nut-loading operation due to a manual process.
Key issues
Speed loss and quality variation occurring during manual operations
Increased operator fatigue and reduced productivity
Operator burden caused by repetitive tasks in the nut insertion process
Objectives
Improve production efficiency by automating repetitive tasks through robot deployment
Secure consistent quality and reduce defect rates through accurate insertion
Improve the work environment by reducing operator fatigue and strengthening safety
Components
| Robot | Hyundai Robotics (HH020-03) Doosan Robotics (H2017) |
|---|
Workflow
| STEP 1. | Pick nuts from the feeder |
|---|---|
| STEP 2. | Insert nuts into the product hole inside the machine tool |
| STEP 3. | After receiving the machine-complete signal, unload the product |
| STEP 4. | Load the product onto the conveyor |
| STEP 5. | Repeat the same sequence with alternating operation. |
Features
Maximized Efficiency
Using robot OLP, pre-validated programs can be uploaded immediately, reducing on-site setup and commissioning time.
Two robots are deployed on a single process for parallel operation, increasing cycle speed and throughput.
Improved Quality
Accurate insertion reduces defect rates.
A vision system is used for final quality inspection.
Flexible Production Environment
Integration of the robot and feeder supports handling multiple nut sizes.
With dedicated robot teaching support, the job can be completed in less time than expected.
Results
| Key Benefits | Productivity improvement: Parallel operation increased process speed by 20%, and continuous robot operation increased output volume. Quality consistency: Precision robot operation reduced defect rates by 15%, and integration with a vision system improved inspection accuracy. Improved work environment: Reduced operator fatigue and injury risk, and helped prevent musculoskeletal disorders caused by repetitive tasks. Lower operating cost: Higher efficiency compared to manual labor reduced overall operating cost. Faster project completion: By using pre-simulation and robot OLP, the project timeline was shortened (completed 20% faster than originally estimated). |
|---|---|
| Client Feedback | The customer stated, “After introducing robots, nut insertion inside the machine tool is now performed faster and more accurately. As a result, we achieved improvements in both process speed and quality. In addition, Marosol’s specialists provided direct teaching support, making on-site deployment very smooth. We were especially impressed with the thorough upfront preparation using OLP.” |
Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
Expanding Form Press Machine Tending using Yaskawa Robots
This machine tending automation solution utilizes YASKAWA robots in conjunction with press machines to automate the loading of workpieces for the expansion of cylindrical metal products, significantly enhancing process safety. Due to the nature of press operations—characterized by extremely short cycle times and high-risk environments—industrial accidents are a frequent concern. By automating the entire sequence from workpiece infeed and discharge to continuous press forming, this solution drastically increases productivity while minimizing the operator's management touchpoints.
Palletizing of 20kg Beverage Boxes using Yaskawa Robots
This heavy-duty palletizing solution utilizes the YASKAWA MH180, a specialized palletizing robot, to automate the stacking of 20kg beverage boxes, handling up to two boxes at once (40kg). By replacing human workers for these high-load tasks, the system prevents musculoskeletal disorders and significantly boosts productivity by handling up to 40kg in a single motion. Furthermore, the robot achieves high transport stability by stacking products in a tightly-packed, staggered (zigzag) pattern, just as a skilled manual laborer would.
Steel Plate Press Assistance using Dual Yaskawa Robots
This automation solution utilizes two YASKAWA robots to assist in steel plate press operations. By automating the machine tending process, the system secures high operational stability and safety. Due to the nature of press processes—characterized by extremely short cycle times and high-risk environments—industrial accidents involving human operators are frequent. In this specific solution, the robots hold the workpieces during the pressing operation itself. By having two robots perform continuous, synchronized cross-work, the cycle time is minimized to just 2 seconds per unit, maximizing overall productivity.