- The introduction of a new product for a cosmetic manufacturing client meant that they had to change their current high speed sorting operation in order to incorporate it into the production system.
- The current amount of mechanical changeovers required for each product was not a preferable method.
- There were six different variations of the product, so the automated solution had to be capable of adjusting to suit different production schedules.
- System required a line speed of 140ppm (parts per minute) to be expandable to 220ppm.
- Parts were to be filled/capped then required to be labelled and grouped into sets of 3 or 6 for auto packaging.
- Customer presented with a detailed project plan in the form of a Gantt chart: timely design reviews with milestone processes showing each stage of the project right through to the installation and site acceptance testing.
- Final outcome was a fully automated production line taking the products from an existing conveyor into a labelling cell then onward to a grouping correlation module and finally feeding an integrated flow wrapping machine.
- 12 components were picked using a ceiling mounted ABB 6-axis robot and placed onto a special purpose servo driven indexing conveyor with machined attachments to suit the products.
- Labelling was then performed as required with various quality inspections carried out on the product before feeding the grouping/correlation robot.
- ABB flexpicker type robot picked 2 parts, rotated 90° and placed them into adjacent machined nests on a servo driven timing belt conveyor.
- As the nested parts travelled through the module a base mounted 6-axis ABB robot picked 6 parts and placed them into a moving conveyor in one group of 6 or two sets of 3.
- Various technologies were utilized for this fast acting cycle. PIAB COAX vacuum cartridges, ABB conveyor tracking technology and servo driven transfers are all combined within a stainless steel fabricated frame to suit the environment.
- All stages focused on creating a positive, value-driven relationship with the client and striving to learn from their wealth of expertise in dealing with this engineering requirement.
Benefit to the Customer
- Future flexibility – new products already added
- Productivity increase – required 140ppm ‘future capability of 220ppm’
- Increased floor space availability
- Modernisation of equipment with high aesthetic properties
- Reduced changeover time