Process layout
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 |
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, βAfter 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. |
|---|
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Curious about the robots used?
![[μ
κ³ μ΅μ κ°] YASKAWA GP250 (Payload : 250kg, Reach : 3490mm)](/_next/image?url=https%3A%2F%2Fd1fchzsdhim61l.cloudfront.net%2FStore%2Fthumbnail%2F191%2F775d76e3-2828-41ee-8d07-8c7d7f664023%2FGP250.png&w=256&q=75)
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