Automated Aerosolized Product Cap Manufacturing Process

An aerosol product cap manufacturing company partnered with Arnold Machine to develop a system that enhances production efficiency by reducing manual labor and streamlining the packaging process. This case study highlights the challenges faced, the solutions implemented, and the positive impact of automation on the company's operations.

Project Overview:

The goal of this project was to automate a significant portion of the manual labor involved in manufacturing aerosolized product caps. The previous process heavily relied on operators to handle tasks such as palletizing, inventory management, and packaging. The company aimed to introduce automation to free up operators, increase production capacity, and optimize overall efficiency.

Timeline and Challenges:

The project spanned 19 months from the receipt of the purchase order until the machine's completion. However, the project faced several challenges:

• Supply Chain Shortages: The original specified parts were unavailable, requiring the redesign of certain sections to accommodate alternative components.
• Limited Motor Drive Manufacturers: The project required CIP safety over ethernet, limiting the selection of motor drive manufacturers to two options.
• Prolonged PLC Debugging: Debugging the PLC took longer than expected, partly due to the customer's request to run partial production through the machine during debugging.
• Mechanical Component Issues: Certain mechanical components did not perform as expected and did not meet the manufacturer's claims. These components had to be replaced, leading to additional delays and adjustments in the system design.
• Box Diversion and Jamming: The boxes did not reliably follow the diverter arms on the conveyor, causing interruptions in the production process as some boxes slid sideways and jammed instead of turning 90° and continuing onto the next conveyor.
• Coordination of System Components: Integrating multiple system components, such as lifting elevators, overhead conveyors, robots, and de-stackers, required meticulous coordination and synchronization, posing a challenge during the implementation phase.
• Data Handling and Database Integration: Setting up real-time data tracking and integration with the SQL database required careful planning and implementation to ensure accurate inventory management and seamless system operation.

Automated Machine Solution:

The automated system was designed to handle multiple stages of the manufacturing process. It featured 4 lifting elevators, an overhead conveyor, a manual pack lane, 2 sets of auto-pack lanes, 4 robots, 2 pallet de-stackers, and an outfeed section with a bander, a wrapper, and 2 label printers.

The process began with authorized users setting up the auto-pack lanes and assigning work order numbers to each sub lane. Mold operators would then place sealed and labeled boxes into the lifting elevators. These elevators carried the boxes to the overhead conveyor, where a barcode scanner read the label, determining the appropriate sorted location based on the work order number.

Upon sorting, the boxes were diverted to the correct packing location. If the target lane had no pallet, a pallet was dispensed from a de-stacker, and the corresponding robot would place a slip-sheet if required. Boxes sent to auto-pack lanes were picked up by robots with vacuum pads and placed on pallets. Once a pallet was full, it was ejected to the outfeed area for banding and/or wrapping. Pallet data was then sent to an SQL database, facilitating inventory management and generating disposition labels for pallets.

Impact on the Company:

The implementation of automation brought significant improvements to the company's manufacturing process. By reducing manual labor and optimizing workflows, operators could now manage three machines simultaneously, leading to increased production capacity. The elimination of manual inventory management and packaging tasks further improved efficiency and reduced errors.

The automated system's ability to scan and sort boxes rapidly without stopping the conveyor significantly increased output, resulting in quicker order processing and delivery. With real-time data tracking and seamless integration into the inventory system, the company experienced enhanced inventory control and improved overall supply chain management.

Conclusion:

The successful automation of the manufacturing process demonstrated the company's commitment to embracing cutting-edge technology and best practices. Despite facing challenges such as supply chain shortages and debugging complexities, the company overcame these obstacles and achieved remarkable results.

The automated system not only increased production capacity but also enhanced operational efficiency, leading to cost savings and improved customer satisfaction. This case study serves as a prime example of how integrating automation into manufacturing processes can have a transformative impact on a company's operations and competitiveness in the market.