Case Study

ERECT I PACK I SEAL

Tubes of Personal Lubricant

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Project Overview

This personal lubricant manufacturer and returning Pearson customer was in need of a solution that would automate the case erecting, packing, and sealing functions of their line, currently staffed by a team of four human operators. They were ready to invest in an automated solution they could count on, as sustaining staff was becoming increasingly difficult.

The solution would need to be flexible enough to handle product pack variations, with minimal disruption to production for changeovers between runs. The customer also hoped to improve operator proficiency across all the equipment, and communicated intent to integrate a uniform palletizer into the line in the future, ideally sourced from the same vendor.

And one final request… powder coat option? Because the machine would need to match their existing purple equipment.

Products and Required Rates

Tubes of personal lubricant (bundled)
120 loose tubes per min/73 bundles per min

Objectives

Eliminate the need for (4) dedicated operators on the line
Minimal downtime for changeovers
Operational consistency
Ability to source a palletizer from the same OEM in the future
3 year ROI

Challenges

Product variation includes individual nested tubes and shrink-wrapped 3- or 6-pack products

Achievements:

Labor Reduction

Freed 4 dedicated operators for other tasks within the organization

Minimal Downtime

Tool-less changeovers to under 10-mins with guided instructions

Improved Usability

Equipment continuity supports operator comprehension & efficiency

Future Line Expansion

Ensured ease of future palletizer integration

Sequence of Operations

A CE35-T tape Case Erector forms boxes, which transport via conveyor to a RTL-MX Robotic Top Loader. As the lubricant tubes enter the cell, a 2D vision system identifies the location of the products and two FANUC M3iA/6S Delta robots equipped with vacuum end-of-arm tooling pick the appropriate product counts and place them horizontally into cases. Filled cases move to the CS25-42T case sealer, where they are securely closed.

A uniform Human Machine Interface (HMI) across all equipment simplifies operation and learning for new staff. Changeovers between loose and bundled product runs require a swap out of the end-of-arm tooling, and can be completed in less than 10 minutes. No tools are required, and the HMI provides a step-by-step guide and changeover map for reference.

Automating the erect, pack and seal functions of the line reduced the manual labor headcount intended by the customer, with the opportunity to purchase and integrate a cohesive robotic palletizer from Pearson into the line in the future. Did we mention the machines were also the perfect shade of PURPLE?

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