Process layout
This automation solution replaces manual plastic product inspection and QR code labeling with a system integrated with vision inspection and four Cartesian (Gantry) robots.
By utilizing four Cartesian robots, the workload is strategically distributed based on the required takt time, enabling rapid and continuous operations. The system performs comprehensive exterior inspections both before and after the QR code is applied, as well as a final attachment verification to minimize defect rates.
The project was initiated to achieve 100% inspection of all products to prevent defects or mixed-part issues, ultimately driving significant quality improvements and productivity gains.
Components
| Robot |
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Workflow
| STEP 1. | Feeding: Input of plastic products into the system. |
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| STEP 2. | Alignment: Precise correction of the product’s position. |
| STEP 3. | Transfer: Loading the products onto the main workstation. |
| STEP 4. | Exterior Inspection: Initial vision check for surface defects or incorrect part types. |
| STEP 5. | QR Labeling: Accurate application of the QR code label. |
| STEP 6. | Verification: Vision inspection of the attached QR code (readability and position). |
| STEP 7. | Sorting: Automatic ejection of defective or mismatched parts. |
| STEP 8. | Palletizing: Loading the verified "Good" products onto the discharge pallet. |
Features
Improved Production Efficiency & Enhanced Quality
Minimized Downtime: Continuous automated operation minimizes idle time, leading to a direct improvement in overall production efficiency.
Zero-Defect Goal: 100% vision inspection is performed on every unit to minimize defect rates and prevent faulty products from reaching the next stage.
Labor Optimization: Reducing the number of manual management points allows for a decrease in required human personnel, lowering operational costs.
Cost-Effective Automation via Cartesian Robots
Compact Installation: Small-scale Cartesian robots allow for a space-saving setup tailored to the existing workspace.
LOB (Line of Balance) Optimization: Workload is strategically distributed across the four robots to eliminate bottlenecks and significantly shorten cycle times.
Results
| Key Benefits | Significant increase in productivity through high-speed automation.
100% quality assurance achieved via integrated vision inspection.
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| Client Feedback | Since our process requires a very short takt time for continuous operation, we needed a highly synchronized system. Nau Technics' solution allowed us to redistribute the workload effectively, enhancing both productivity and quality simultaneously.
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