The challenge
Operators had to handle heavy metal trays of parts by hand and move between production stations, which created a heavy physical load.
One of the main challenges was reducing the physical load and the number of manual operations involved in handling the trays and organising the flow of material on the line. Finished products were transported in metal trays holding 50 parts each.
The outcome
We designed and commissioned a complete transport and packing system: a roller conveyor with three buffer zones and a station that rotates the tray 180° automatically on servo drives.
The conveyor automatically collects trays of products from the oven and moves them to the packing station. The operator does no more than place the carton on the parts, while the most demanding part of the process has been taken over by the machine.
Once the cycle starts, the system automatically positions the tray, lifts it with servo drives, secures it against movement and performs a controlled 180° rotation. The tray is then set down on the conveyor in a position that allows further packing and closing of the carton.
- automatic roller conveyor moving trays between production stations, built on Interroll components
- three independent transport zones allowing production to be buffered
- automatic tray queuing using a set of Balluff sensors
- packing station with automatic 180° tray rotation
- servo-driven lifting and rotation system from Siemens giving the process high repeatability
- FESTO pneumatic systems for locking and positioning the tray during rotation
- verification that the carton is correctly fitted, using laser and optical sensors
- HMI operator panel allowing full process parameterisation
- Keyence light curtains and interlocked safety doors for safe operator interaction with the machine
- structure designed to improve working ergonomics and cut unnecessary operator movement
What set this project apart?
Unlike typical assembly automation projects, the main goal here was not to replace the operator in the production process, but to relieve them of the most physically demanding tasks.
The greatest value of the implementation was handing the handling of the tray of parts over to the machine. The operator no longer has to rotate a heavy load by hand or carry out additional work to position it. The system automatically picks up the tray, secures it, rotates it 180° and sets it down in the right position for the packing process that follows.
The project was a good example of using automation not only to increase throughput, but also to improve working ergonomics and operator safety.
A few numbers that sum this project up:
- Tray capacity
- 50 parts
- Weight of a loaded tray
- 20 kg
- Target line throughput
- 2 300 pcs/h
- Machine OEE
- >99%
- Automatic rotation
- 180°
- System dimensions
- ~7 000 × 3 000 mm
Results of the implementation
- No more manual rotation of heavy trays of parts
- Less physical effort for operators
- Fewer movements between workstations
- Smoother flow of material along the production line
- Better safety and ergonomics at the workstation
- Repeatable and controlled packing process
- Production can be buffered between operations
- High process availability and reliability
„The operators felt the biggest change. The machine took over the most physically demanding work of handling the trays, and transport between stations now happens automatically. The process is more ergonomic, safer and more repeatable as a result."
- Production manager (ATIV client)
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Industrial automation projects - ATIV technical documentation
We document how the automation projects we deliver for clients across industry actually ran. Each description covers the technical challenge, the hardware and software used, the stages of the work and the measurable results of the implementation - shorter cycle time, fewer rejects, higher output per shift or better process repeatability.
We deliver projects for the automotive (IATF 16949), FMCG, aerospace (AS9100), electronics and medical (ISO 13485) sectors. Experience with industry standards translates into machines that meet audit requirements and are straightforward for a client's quality department to validate.
Full project documentation - technical drawings, electrical diagrams, the PLC program, the operating manual and the validation report - is supplied as standard with every implementation. Get in touch to receive reference material matched to your industry.