TIDI Merchandise, a worldwide producer of an infection prevention and affected person security merchandise, remodeled its end-of-line operations by automating with Lean Palletizing. The consequence: measurable features in productiveness, safer working circumstances, and extra environment friendly use of labor.
This case reveals 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 features (subsequent cells)
- 2× efficiency enchancment by combining work cells
- Diminished labor from two operators to at least one per cell
- Vital discount in pressure and harm threat
The issue: handbook palletizing restricted manufacturing capability
Earlier than automation, palletizing at TIDI Merchandise was absolutely handbook. 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 important 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 compelled to say no orders.
Not solely was handbook 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 offered:
- Constant palletizing efficiency
- Flexibility throughout product strains
- Quick operator adoption because of ease of use
This allowed the workforce to shortly transfer from handbook dealing with to a scalable, automated course of.
Consequence 1: 30% productiveness enhance within the first deployment
The primary palletizing cell delivered a 30% enhance in productiveness.
This quick acquire got here from:
- Eliminating handbook dealing with time
- Lowering operator motion between stations
- Rising total line pace
For producers evaluating ROI, this reveals how a single automation mission can shortly unlock capability.
Consequence 2: Repeatable features 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.
Consequence 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 at least one
- Uptime elevated throughout operations
It is a key perception: robotic palletizing doesn’t simply automate duties; it permits course of redesign for larger throughput.
Consequence 4: lowering labor constraints whereas growing effectivity
Labor challenges had been a serious driver for automation.
After deployment:
- One operator can now handle a number of processes
- Staff give attention to higher-value duties like machine operation
- General effectivity improves with out growing headcount
This helps producers preserve output even in tight labor markets.
Consequence 5: enhancing employee security and ergonomics
Guide 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:
- Damage dangers had been considerably diminished or eradicated
- Bodily pressure on staff decreased
- Jobs grew to become much less bodily demanding
Enhancing ergonomics additionally helps long-term workforce retention.
Consequence 6: constant output and improved product high quality
Guide palletizing required coaching and nonetheless launched variability.
Automation delivered:
- Constant pallet patterns
- Diminished 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 larger efficiency
TIDI Merchandise achieved:
- 30% productiveness features 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 considerations, palletizing automation presents a transparent path to enchancment.
Discover out if palletizing automation is best for you
Unsure in case your utility is an efficient match for Lean Palletizing?
Use our Palletizing Match Instrument to shortly consider your palletizing wants and see if automation can ship comparable leads to your operation.
