TIDI Merchandise, a world producer of an infection prevention and affected person security merchandise, reworked its end-of-line operations by automating with Lean Palletizing. The outcome: measurable positive aspects in productiveness, safer working circumstances, and extra environment friendly use of labor.
This case reveals how robotic palletizing can immediately enhance manufacturing efficiency with clear, repeatable outcomes.
Key outcomes at a look
- 30% improve in palletizing productiveness (first cell)
- 25% extra productiveness positive aspects (subsequent cells)
- 2× efficiency enchancment by combining work cells
- Decreased labor from two operators to at least one per cell
- Vital discount in pressure and harm threat
The issue: guide palletizing restricted manufacturing capability
Earlier than automation, palletizing at TIDI Merchandise was totally guide. Operators dealt with a number of duties, together with:
- Constructing packing containers
- Filling and sealing them
- Transporting and stacking them on pallets
This created two crucial bottlenecks:
Labor inefficiency
One operator usually needed to handle a number of stations, decreasing focus and throughput.
Manufacturing delays and misplaced income
Backlogs elevated, and the corporate was pressured to say no orders.
Not solely was guide palletizing sluggish, it prevented the corporate from scaling.
The answer: Robotiq Lean Palletizing
TIDI Merchandise deployed Robotiq palletizing options to automate repetitive and bodily demanding duties on the finish of the road.
The system supplied:
- Constant palletizing efficiency
- Flexibility throughout product traces
- Quick operator adoption because of ease of use
This allowed the workforce to rapidly transfer from guide dealing with to a scalable, automated course of.
End result 1: 30% productiveness improve within the first deployment
The primary palletizing cell delivered a 30% improve in productiveness.
This speedy acquire got here from:
- Eliminating guide dealing with time
- Lowering operator motion between stations
- Growing total line pace
For producers evaluating ROI, this reveals how a single automation challenge can rapidly unlock capability.
End result 2: Repeatable positive aspects throughout a number of cells
After the preliminary success, extra palletizing cells had been deployed.
Every new cell delivered:
- 25% productiveness enhancements on common
This demonstrates an necessary precept of automation: as soon as a course of is standardized, enhancements grow to be repeatable and scalable.
End result 3: Doubling output by redesigning the workflow
Automation enabled TIDI Merchandise to rethink its manufacturing format.
By combining two workstations into one:
- Output per cell doubled
- Operator necessities dropped from two to at least one
- Uptime elevated throughout operations
This can be a key perception: robotic palletizing doesn’t simply automate duties; it allows course of redesign for greater throughput.
End result 4: decreasing labor constraints whereas growing effectivity
Labor challenges had been a significant driver for automation.
After deployment:
- One operator can now handle a number of processes
- Staff give attention to higher-value duties like machine operation
- Total effectivity improves with out growing headcount
This helps producers preserve output even in tight labor markets.
End result 5: bettering employee security and ergonomics
Handbook palletizing required repetitive lifting of packing containers weighing as much as 25 lbs (11kg).
This led to:
- Strains and sprains
- Fatigue and misplaced workdays
With robotic palletizing:
- Harm dangers had been considerably decreased or eradicated
- Bodily pressure on employees decreased
- Jobs turned much less bodily demanding
Enhancing ergonomics additionally helps long-term workforce retention.
End result 6: constant output and improved product high quality
Handbook palletizing required coaching and nonetheless launched variability.
Automation delivered:
- Constant pallet patterns
- Decreased coaching time
- Extra dependable output
This results in higher product high quality and improved buyer satisfaction.
Why this issues for producers contemplating palletizing automation
This case highlights how robotic palletizing improves:
- Manufacturing throughput
- Labor effectivity
- Office security
- Operational consistency
Most significantly, the outcomes are measurable and repeatable.
Conclusion: a quick, scalable path to greater efficiency
TIDI Merchandise achieved:
- 30% productiveness positive aspects instantly
- Continued enhancements with every new deployment
- Safer, extra environment friendly operations
Their recommendation is straightforward: Automate sooner to unlock outcomes quicker.
For producers coping with labor shortages, manufacturing bottlenecks, or security considerations, palletizing automation provides a transparent path to enchancment.
Discover out if palletizing automation is best for you
Undecided in case your utility is an efficient match for Lean Palletizing?
Use our Palletizing Match Software to rapidly consider your palletizing wants and see if automation can ship related ends in your operation.
