Automating the end of your production line is a significant investment that can enhance efficiency, improve quality, and reduce labor costs. However, if certain topics are not properly addressed before implementing an automated end-of-line solution, several issues may arise during the implementation phase, such as overspending, considerable delays, decreased efficiency, or end-user inadaptability.
So you have received the new piece of equipment that everybody has been talking about and waiting for... That's exciting! But did you know that there are several key aspects that businesses and project engineers should consider before commiting to an install to ensure a smooth transition and long-term success. Based on our experience, the following is a list of some key aspects, among others, that are often overlooked and play a crucial role in the long-term success of any automation project.
1. Trained and Capable Staff
Even the most advanced automation solutions require skilled operators to manage and maintain them. Proper training must be part of the scope of delivery for automation projects, not only for daily operators but also for maintenance technicians and engineering-level staff. A good practice that saves significant time during training is onboarding the operators during the conceptualization and engineering phase of the project. No one has more knowledge about common issues and product properties than those who handle them daily. This proactive approach ensures a greater understanding of the system's functionality, key aspects, troubleshooting, and capacity, ultimately leading to improved performance and reduced downtime.
2. Upstream Process Quality Control
Automation works best when the incoming product is consistent and meets quality standards. This is one of the most overlooked aspects when switching from manual operations to automated systems. Many product or process conditions are not previously known or have not been addressed due to the flexibility and adaptability that manual operations provide. Certain products or industries require inspection before secondary packaging, an operation often carried out by human packers due to their ability to multitask and use the most advanced vision and touch sensing system -our incredible pair of eyes and naturally complex hands— to detect defects. Fortunately, modern automated systems offer several ways to achieve effective quality inspections without excessive complexity or cost, making automation feasible for packaging projects.
3. Safety Concerns and Requirements
End-of-line automation must comply with workplace safety regulations. This includes integrating safety fencing, emergency stop mechanisms, and ensuring that employees are trained in operating and interacting safely with automated equipment. During the dimensioning of the solutions end users and customers must determine their required safety standards or communicate their safety concerns to system providers to mitigate risks of injuries or fatalities. A good and experienced system integrator should be able to guide the customer in determining the appropriate PL:r (Required Performance Level) according to their expectations and the risks involved with the operation. By doing this, both end users and integrators will have a clear roadmap and certainty regarding safety system expectations and design. Not having a baseline for safety standards can lead to costly delays, additional system modifications, or, more critically, injuries and fatalities.
4. Packaging Materials and Required Adjustments
Automated packaging solutions may require modifications to packaging materials. Ensuring that boxes, trays, films, and other packaging components are compatible with automation can prevent unnecessary disruptions and inefficiencies. A good practice is to actively involve packaging engineers and packaging material vendors during the engineering phase of a solution. By doing so, more key aspects of the process can be identified, and necessary adjustments can be made in a timely manner to prevent efficiency losses or prolonged and frustrating FAT protocols and commissioning periods for the equipment.
5. Throughput and Efficiency Expectations
Define clear production goals and ensure the automation system aligns with your required throughput rates. Consider factors such as machine cycle times, bottlenecks, and peak production demands.
6. Growth Planning and Overhead Capacity
Investing in automation should consider future growth. Ensure that your system has the flexibility and scalability to accommodate increased production volumes, new product lines, or additional automation modules as your business expands.
By addressing these key aspects amongst others, businesses can better prepare for the successful implementation of end-of-line automation, ensuring seamless integration and long-term efficiency gains.
Having an experienced partner like Odecopack can be crucial in guiding customers through the appropriate selection of equipment and necessary adjustments to the process, ensuring the success of an automation project. This expertise is especially valuable in helping businesses navigate the complexities of automation and achieve optimal efficiency and performance.
For more insights and automation solutions, visit www.odecopack.us.
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