Process layout
Process Overview
This deployment uses a YASKAWA GP180 to palletize boxes of hanger products weighing over 20 kg onto pallets. By replacing manual handling in heavy-payload work, it helps prevent musculoskeletal disorders and enables faster, more consistent palletizing performance.
Note: Cost may vary depending on the installation environment, robot brand, and payload requirements.
Components
| Robot | YASKAWA GP180 Horizontal reach: 2,702 mm Repeatability: ±0.2 mm |
|---|---|
| Peripherals | Communication / control: Choose one (PC control or PLC control) Robot mounting base: within 1,200 mm (height) Box gripper: designed for 10–20 kg class (suction + gripper type) Belt conveyor: 1,300 × 220 × 640 mm (for infeed and outfeed) Touch screen: 12" Safety fence: 12 m (includes safety S/W) |
Workflow
| STEP 1. | Boxes are conveyed in and aligned |
|---|---|
| STEP 2. | The robot picks the box |
| STEP 3. | The robot palletizes (stacks) the box onto the pallet |
| STEP 4. | (Optional) Box taping and wrapping process. |
Features
Stable, reliable handling and palletizing/stacking operations.
Stacking orientation can be customized to maximize pack density and loading efficiency.
Tight, close-packed stacking between workpieces enables uniform, stable loads throughout the palletizing process.
Boosts productivity while improving the shop-floor work environment at the same time.
Rapidly palletizes high-weight cartons (20 kg+) to maximize throughput.
Minimizes idle time and helps prevent operator musculoskeletal disorders (MSDs).
Results
| Key Benefits | Improves productivity by enabling uninterrupted operation with minimal idle time.
Increases palletizing efficiency through uniform and stable stacking. |
|---|---|
| Client Feedback | The customer noted that heavy boxes needed to be stacked high on pallets, but it was difficult and time-consuming due to physical constraints on operators. By introducing a palletizing robot, they were able to stack loads faster and higher with consistent quality, significantly improving productivity. |
Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
High-Payload Logistics Success! Lead Tab Automatic Transfer with OMRON AMR
This implementation case demonstrates the automation of heavy product transportation using Omron AMR Logistics . The client introduced a Logistics automation system to reduce inefficiencies and labor burdens arising from repetitive and heavy Logistics tasks. In particular, they aimed to reduce costs and maximize Logistics efficiency through the automation of palletizing and return operations. By automating the simple, repetitive tasks of product movement and stacking, this solution increased the efficiency and accuracy of the outbound process, reduced the burden on workers, and enhanced safety and productivity.
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Aluminum Dross Processing using Yaskawa Robots
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Process layout
Process Overview
This deployment uses a YASKAWA GP180 to palletize boxes of hanger products weighing over 20 kg onto pallets. By replacing manual handling in heavy-payload work, it helps prevent musculoskeletal disorders and enables faster, more consistent palletizing performance.
Note: Cost may vary depending on the installation environment, robot brand, and payload requirements.
Components
| Robot | YASKAWA GP180 Horizontal reach: 2,702 mm Repeatability: ±0.2 mm |
|---|---|
| Peripherals | Communication / control: Choose one (PC control or PLC control) Robot mounting base: within 1,200 mm (height) Box gripper: designed for 10–20 kg class (suction + gripper type) Belt conveyor: 1,300 × 220 × 640 mm (for infeed and outfeed) Touch screen: 12" Safety fence: 12 m (includes safety S/W) |
Workflow
| STEP 1. | Boxes are conveyed in and aligned |
|---|---|
| STEP 2. | The robot picks the box |
| STEP 3. | The robot palletizes (stacks) the box onto the pallet |
| STEP 4. | (Optional) Box taping and wrapping process. |
Features
Stable, reliable handling and palletizing/stacking operations.
Stacking orientation can be customized to maximize pack density and loading efficiency.
Tight, close-packed stacking between workpieces enables uniform, stable loads throughout the palletizing process.
Boosts productivity while improving the shop-floor work environment at the same time.
Rapidly palletizes high-weight cartons (20 kg+) to maximize throughput.
Minimizes idle time and helps prevent operator musculoskeletal disorders (MSDs).
Results
| Key Benefits | Improves productivity by enabling uninterrupted operation with minimal idle time.
Increases palletizing efficiency through uniform and stable stacking. |
|---|---|
| Client Feedback | The customer noted that heavy boxes needed to be stacked high on pallets, but it was difficult and time-consuming due to physical constraints on operators. By introducing a palletizing robot, they were able to stack loads faster and higher with consistent quality, significantly improving productivity. |
Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
High-Payload Logistics Success! Lead Tab Automatic Transfer with OMRON AMR
This implementation case demonstrates the automation of heavy product transportation using Omron AMR Logistics . The client introduced a Logistics automation system to reduce inefficiencies and labor burdens arising from repetitive and heavy Logistics tasks. In particular, they aimed to reduce costs and maximize Logistics efficiency through the automation of palletizing and return operations. By automating the simple, repetitive tasks of product movement and stacking, this solution increased the efficiency and accuracy of the outbound process, reduced the burden on workers, and enhanced safety and productivity.
Smartphone Transfer using TechFloor Mobile Manipulator (M6X)
This transfer automation solution utilizes the TechFloor Mobile X, a high-performance Mobile Manipulator, to pick smartphones from shelving units, load them onto its onboard platform, and transport them to the next process stage. The TechFloor Mobile X can be deployed without extensive infrastructure changes and offers flexible adaptation to layout or workstation modifications. It ensures high productivity through rapid transit and high-precision docking, minimizing common mobile robot issues such as alignment errors. By applying this solution to environments with frequent inter-process part transfers, continuous operation is achieved regardless of shifts, significantly boosting productivity without additional labor costs.
Aluminum Dross Processing using Yaskawa Robots
This automation solution utilizes YASKAWA robots to automate the hazardous manual process of handling high-temperature aluminum dross (a byproduct of molten aluminum). By deploying a robot with high heat resistance, this system replaces human operators in extreme thermal environments, ensuring workplace safety and enabling continuous, non-stop operation. The primary goal of this project was to enhance operational safety and improve the work environment by automating the byproduct treatment following high-heat aluminum processing.