TIDI Merchandise, a world producer of an infection prevention and affected person security merchandise, remodeled its end-of-line operations by automating with Lean Palletizing. The outcome: measurable positive aspects in productiveness, safer working situations, and extra environment friendly use of labor.
This case exhibits how robotic palletizing can instantly enhance manufacturing efficiency with clear, repeatable outcomes.
Key outcomes at a look
- 30% enhance in palletizing productiveness (first cell)
- 25% further productiveness positive aspects (subsequent cells)
- 2× efficiency enchancment by combining work cells
- Decreased labor from two operators to 1 per cell
- Important discount in pressure and damage 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 containers
- Filling and sealing them
- Transporting and stacking them on pallets
This created two vital bottlenecks:
Labor inefficiency
One operator typically needed to handle a number of stations, lowering focus and throughput.
Manufacturing delays and misplaced income
Backlogs elevated, and the corporate was pressured to say no orders.
Not solely was guide palletizing gradual, 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 on account of ease of use
This allowed the workforce to rapidly transfer from guide dealing with to a scalable, automated course of.
Outcome 1: 30% productiveness enhance within the first deployment
The primary palletizing cell delivered a 30% enhance in productiveness.
This speedy acquire got here from:
- Eliminating guide dealing with time
- Lowering operator motion between stations
- Growing general line velocity
For producers evaluating ROI, this exhibits how a single automation mission can rapidly unlock capability.
Outcome 2: Repeatable positive aspects throughout a number of cells
After the preliminary success, further 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 turn out to be repeatable and scalable.
Outcome 3: Doubling output by redesigning the workflow
Automation enabled TIDI Merchandise to rethink its manufacturing structure.
By combining two workstations into one:
- Output per cell doubled
- Operator necessities dropped from two to 1
- Uptime elevated throughout operations
This can be a key perception: robotic palletizing doesn’t simply automate duties; it permits course of redesign for increased throughput.
Outcome 4: lowering labor constraints whereas rising effectivity
Labor challenges had been a significant driver for automation.
After deployment:
- One operator can now handle a number of processes
- Employees concentrate on higher-value duties like machine operation
- General effectivity improves with out rising headcount
This helps producers preserve output even in tight labor markets.
Outcome 5: bettering employee security and ergonomics
Handbook palletizing required repetitive lifting of 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 diminished or eradicated
- Bodily pressure on employees decreased
- Jobs turned much less bodily demanding
Bettering ergonomics additionally helps long-term workforce retention.
Outcome 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 increased 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 sooner.
For producers coping with labor shortages, manufacturing bottlenecks, or security issues, palletizing automation gives a transparent path to enchancment.
Discover out if palletizing automation is best for you
Unsure in case your software is an efficient match for Lean Palletizing?
Use our Palletizing Fit Tool to rapidly consider your palletizing wants and see if automation can ship related leads to your operation.
