In an ever-evolving food and beverage production environment, manufacturing continues to struggle for decades with job vacancies, supply chain instability, and changing consumer behavior. The impact of the global pandemic has exacerbated these problems, leading to lower job retention and recruitment rates in the manufacturing sector.
From recent statistics CNBC reports that more than 50 million people will be out of work in 2022.. The article goes on to emphasize that “most people quit their job to get a new job, not to leave it completely.” (CNBC). The amount of job opportunities available and competitive wages have contributed to this trend.
The manufacturing dilemma is: Products have to be stacked on pallets, and people don’t want to do that. People are moving away from manual, repetitive and dangerous tasks. U.S. Chamber of Commerce in Durable Goods Manufacturing 45% of open positions remain unfilled. Only in the US. Universal Robots estimates: 250,000 people Stack pallets worldwide. Assuming 50% of available jobs are filled, 500,000 people will need to manually palletize products. However, manufacturing uses half the workforce required for this task.
Companies are increasingly adopting automation as employees pursue more rewarding roles. In industries such as food and beverage manufacturing, automation is essential, especially in tasks such as palletizing. Lean Robotics offers a smart approach to integrating lean manufacturing principles into automated solutions. By leveraging Lean Robotics, companies can develop automated palletizers that meet their current and future needs. In addition to job retention issues, this solution addresses: We help businesses maintain control, prioritize customer needs, and simplify expansion.
Maintain process control
Operations managers want to overcome labor shortage issues and create adaptive processes that allow for flexibility. all Case study conducted by Robotiq It highlights Cascade Coffee, a contract roasting and packaging company that had difficulty finding manual palletizing workers. There was a turnover rate of over 60%. The constant need for training consumed leadership time and resulted in machine downtime. In this case, automation solved these problems, allowing the company to run smoothly without human intervention.
Lean Robotics palletizing systems match the usability of collaborative robot (cobot) software with the hardware configurability of custom systems. The advantage of Lean Robotics palletizing systems lies in their user-friendly design and the fact that anyone in the manufacturing team can operate them. Using this type of system does not require highly specialized skills or extensive training. This accessibility allows all team members to quickly become familiar with the system, regardless of their role or previous experience. The integration of hardware and software makes it easy to use, allowing manufacturing teams to focus on their core responsibilities without the complexity of operating complex machinery. Download our Buyer’s Guide to learn more about the types of palletizing solutions available on the market.
Reflecting customer requirements in the driver’s seat
Automated palletizing solutions must seamlessly adapt to changing demands at the end of the production line. A variety of solutions are available, from custom engineered robots to out-of-the-box cobot solutions. The most adaptable options are in the middle of this range, providing a foundation of engineered components optimized for rapid implementation. This is a lean robotics solution.
Lean robotic solutions offer user-friendly configuration features. This allows operators to adjust both software settings and the hardware itself. This eliminates the need for extended downtime, complex reprogramming, and costly external expertise. Likewise, lean robotic solutions allow operators to change box sizes and pallet patterns as needed.
Lean Robotics solutions provide intuitive software and modular hardware so teams can autonomously implement reconfigurations. The adaptability of these solutions is evident in their ability to accommodate a variety of case sizes, weights and pallet heights.
But lean robotics is more than just dimensions and measurements. Lean Robotics has the adaptability to adapt to a variety of situations, such as changing physical environments, adding pallet mid-layer sheets, or the need to accommodate multiple conveyors. This adaptability allows plants to respond instantly to changing market demands, enabling real-time adjustments without the need for extended downtime, complex reprogramming, or expensive external expertise.
Simplify scaling
Effective scaling is critical to any investment, whether responding to sudden surges in demand or organic growth. This is a benefit of Lean Robotics development solutions. The modular design and comprehensive range of solutions simplify the process when duplicating or adding new devices. Lean robotics solutions speak the same language, so users only need to learn the software once. Subsequent expansions and additional devices leverage the same software to make growth even easier.
Lean robotics palletizers are built and operated according to lean manufacturing principles. Unlike other methods where suppliers or technology determine layout or material flow, this approach supports continuous improvement efforts on the factory floor. These palletizing solutions are built on collaborative robots. It keeps the operator in mind, leveraging built-in functionality, inherent simplicity and the possibility to integrate seamlessly into existing layouts.
Unlike other types of solutions that sacrifice performance, this category of solutions offers reliability and interoperability, advanced control software, flexible tools, and a user-friendly configuration interface for rapid deployment.
To learn more about different solution types, download our Buyer’s Guide..
Lean robotics palletizer:
- Optimize material flow in the cell.
- Available for updates and improvements
- We may add new products over time.
The modularization of standard elements (e.g. end-of-arm tools, stands, slip racks, etc.) allows efficient deployment while maintaining sufficient flexibility to handle the inevitable characteristics of the plant and product.
Integration of hardware and software components not only simplifies operations but also contributes to the financial viability of automation initiatives. Automated palletizers typically offer a payback period of one year, making investing in automation economically viable. Find case studies of companies benefiting from Robotiq palletizing solutions. From the Robotique website
conclusion
The manufacturing sector, especially food and beverage production, is constantly changing. The challenges associated with finding blue-collar workers have become even worse in the wake of the global pandemic. The reluctance of personnel to engage in manual and repetitive tasks has led to severe labor shortages. This is particularly serious in palletizing operations, where turnover in some companies is over 60%. Food and beverage manufacturing is turning to automated palletizing solutions because continuous turnover is unsustainable.
Automation in the food industry not only solves job retention issues, it also helps companies maintain control, prioritize customer needs, and streamline expansion. By adopting lean robotics solutions, companies can enable anyone on the manufacturing team to operate palletizers. They are flexible enough to respond to customer changes and can scale as your business grows.
move
Not sure where to start? We’ve created a comprehensive Buyer’s Guide to help you get started. We use our years of experience to create step-by-step processes and the tools you need.
Ready to get started? Talk to our palletizing experts.
