Side By Side: A Case for Collaborative Robots

When robots first entered the manufacturing work force in the mid-twentieth century, they were installed to perform heavy or dangerous (or both) tasks, over and over again alongside other robots. Where it was impractical to put the robots in rooms of their own, expensive and space-consuming safety guarding was required to protect humans from colliding with the machines that could neither sense their presence nor account for the fragility of the human skeleton. As robot technology advanced, the machines became smaller, lighter, nimbler, and more useful in manufacturing processes.

No longer confined to spot welding and painting, robots are now deployed throughout the factory floor. Today, robotic systems can be found in modern manufacturing plants loading bulk materials into feeders, and assembling a wide range of consumer goods and medical devices. Very small robots with high-speed picking capabilities have been developed that can quickly sort or collate parts, assemble kits, and inspect finished goods. Mid-sized multi-axis robotic units are used for packing those goods into cartons, bags, and blisters, and then inspecting the packaged goods. Larger robots with payloads up to hundreds of pounds also handle end-of-line processes such as case packing and palletizing.

Dual Pallet Cell with Collaborative CR-35iA Robot. (Photo copyright ESS Technologies.)

By automating manual processes, especially case packing and palletizing, manufactures can reduce workplace injuries caused by lifting heavy cases or performing repetitive motions. The cost for factory floor space is not insignificant, however, and while the uses for robots in manufacturing evolved, the safety guarding systems, for the most part, did not. Requiring additional factory floor space, PLe-rated safety guarding systems, the standard for robotic cells, include a combination of wire fences, polycarbonate walls, and sensors that, when tripped, cause the robot to stop all activity within the cell. Opening a guard door or tripping a light curtain or area sensor generates a fault in the robotic PLC that must be addressed by the operator before automatic operation can resume.

The development of collaborative robots, such as FANUC America’s CR-35iA robot, marks a new generation of robotic technology. The CR-35iA offers a payload of up to 35kg and a reach of 1,813mm, making it ideal for automating manual palletizing processes. In addition to eliminating heavy lifting for employees, the collaborative robot further increases workplace safety, because the robot itself is designed to operate in close proximity to humans in a shared workspace without the need for safety fences. The green robot cover is padded to reduce impact forces and pinch points by providing a soft barrier between a human operator and a robot arm. The stopped robot arm can be gently pushed away from people or objects by the operator if needed.

The CR-35iA Collaborative Robot features twenty-four (24) precision sensors that cause it to stop all motion when it comes in contact with an object or person. This eliminates the need for safety guarding and greatly reduces the footprint of the robotic cell. Without guarding, the CR-35iA will operate up to two (2) cycles per second. Greater speeds can be achieved (5-6 cycles per minute) with the use of area sensors to detect motion within the robotic cell. Well-designed robot end-of-arm tooling (EOAT) allows the robot to pick more than one case, depending on the case size and weight, further reducing the time needed to form a full pallet load. In applications requiring placement of a deck sheet or tier sheet, the same robot and tooling performs these functions. When integrated with serialization track-and-trace systems, the robot may also be programmed to hold case labels over cameras or barcode scanners to verify the pallet load or provide automatic reject of incorrectly labeled cases.

FANUC America has recently expanded its line of collaborative robots to include compact versions, the CR-4iA with a 4kg payload and the CR-7iA/L with a 7kg payload, that can be integrated to perform a wide range of manufacturing and packing processes.  Like their larger counterpart, the smaller collaborative robots also include sensors to allow the robot to detect a collision and automatically cease operation. As collaborative technology evolves, expect to see robots working side-by-side with humans in all manner of manufacturing processes.

FANUC America Collaborative Robots (Photo copyright FANUC America. ESS Technologies is an authorized FANUC system integrator.)

Robotic Palletizers for Track and Trace Serialziation

(This is part threein a three-part series on integrating packaging machinery with track and trace serialization systems to meet the 2017 pharmaceutical mandates. Part one is here. Part two is here.)

Track & Trace Pallet Cells

Robotic palletizers also integrate easily with track and trace systems. Prior to palletizing, labeled cases are verified at the case infeed conveyor. The system either presents the label to the barcode reader or a barcode reader positioned on the conveyor can read the label before the case is picked. In either scenario, incorrect cases can be rejected for rework. Robots can also be programmed to position the case label so that it can be seen and scanned at pallet’s final location.

Barcode Scanners at a Palletizer Infeed

Robotic palletizers can be integrated directly with track and trace case packers to create a complete end-to-end system. High speed case packers integrated with stand-alone robotic pallet cells can handle up to 20-25 cases per minute using two robots, one to case pack and one to palletize. Track and trace packaging lines requiring lower speeds, between 5-6 cases per minute, can incorporate case packing and palletizing with a single robot to create a very compact track and trace packaging solution.  Labelers and scanners are also integrated with robotic palletizers. Fully loaded pallets are also labeled using RFID tags, bar codes or readable codes to fully verify the contents of the pallet.

Single Cell Robotic Palletizer with Integrated Serialization System

By integrating OEM serialization systems with packaging machinery, pharmaceutical manufacturers can secure their supply line from counterfeiting and meet current and future pedigree requirements. The investment in integrated equipment provides a streamlined process that can be easily reconfigured for future applications.

Dual Cell Robotic Palletizer with Integrated Serialization System

The Ergonomics of Automation

As an integrator for FANUC Robotics, North America, ESS has given a good deal of discussion to the advantages of increased productivity achievable when manufacturers automate their manual processes. A number of factors contribute to the increased production, including faster speeds, improved material handling, and reduced downtime associated with changeover. The ergonomics of automation are less widely discussed, but reducing workplace injuries also increases productivity and can save manufacturers thousands of dollars in lost productivity and worker’s compensation.

Ergonomic Injuries by the Numbers

According to the Bureau of Labor Statistics (BLS), “Musculoskeletal disorders (MSDs), often referred to as ergonomic injuries, accounted for 28 percent of all workplace injuries and illnesses requiring time away from work...[i] MSDs include sprains and strains, inflammation, degeneration, tears, pinched nerves or blood vessels, bone splintering and stress fractures. Repetitive motion injuries, such as carpal tunnel syndrome fall into this category as well.

A research paper published earlier this year, “An Ergonomic Investigation of the Case Packing Line at Company XYZ”[ii] provides a succinct analysis of the types of injuries and their impact on a manual case packing operation. The paper concludes that the most common injuries were associated with the wrist and the back.[iii] Back injuries are most commonly the result of improper lifting techniques; wrist injuries are caused by cumulative trauma disorders (CDTs), such as carpal tunnel syndrome and tendonitis. In this particular study, seven OSHA recordable injuries totaled more than $59,000 in workers compensation claims over a four year period.[iv] While the paper did not include data for manual palletizing processes, it is not hard to imagine a similar injury rate for that physically demanding process. Data from the BLS further underscores the lost of productivity due to workplace injuries, for example:

·         3,277,700 total reportable injuries; 965,000 of those injuries resulted in time missed from work

·         379,340 injury reports involved sprains, strains, and tears; 11% of those injuries (43,100) occurred to workers in the manufacturing industry

·         195,150 back injuries were reported; 10% (20,540) occurred to workers in the manufacturing industry [v]

The study of the case packing line concluded that, “The case-packing process should be further investigated in order to implement changes that will reduce the ergonomic risk factors currently present.”[vi]

Automation Solutions

Robotics automation offers a quick and relatively uncomplicated solution to reducing the ergonomic risks of both manual case packing and palletizing processes. Robotic case packers can quickly collate and load cases of product, and often these systems require less floor space than manual case packing stations. While the case packer still requires human intervention to run the machine and re-load the case magazine, the repetitive motions are handled by the robot, which cannot be injured.

Robotic pallet cells also require a human operator, mainly to operate the pallet jack to move pallets into and out of the pallet cell, but the robot handles the case lifting and stacking motions, again reducing the risk of injury to personnel. Even assembly and material handling processes can present an injury risk to employees. Assembly processes very often include repetitive processes that can lead to carpal tunnel syndrome or tendonitis, as can some material handling processes. For example, hand feeding a high speed blister packaging machine can require anywhere from one to six people to repetitively load blisters with product. Robots today have the dexterity needed for many assembly and material handling processes, allowing human personnel to be reassigned to duties that are less likely to cause injury.

Conclusion

Looking at the bottom line only, by reducing the risk of injury to their personnel, manufacturers can realize decreased downtime due to employee absence as well as decreased worker’s compensation costs. This may lead to increased profitability, which may, among other things, allow manufacturers to avoid relocating their factories to countries with lower wages in order to reduce overhead costs. Factor in the human equation and calculate the number of injuries not suffered by employees, and manufacturers can clearly see the ergonomic advantages of automating manual processes.

[i] Bureau of Labor Statistics (11/9/2010) “Nonfatal Occupational Injuries and Illnesses Requiring Days Away From Work, 2009.” Retrieved from http://www.bls.gov 10/14/2011.

[ii] Schmidt, J. (2011) An Ergonomic Investigation of the Case Packing Line at Company XYZ. Retrieved from http://www2.uwstout.edu/content/lib/thesis/2011/2011.schmidtjos.pdf 10/14/2011.

[iii] Ibid, p. 34.

[iv] Ibid, p. 49.

[v] Bureau of Labor Statistics “Latest Numbers.” Retrieved from http://www.bls.gov/IIF/ 10/14/2011.

[vi] Schmidt, p. 38.

---

End of Line Packaging Trends

It seems these days, no matter what part of the packaging process one is talking about, automation is the word. This is also true for end-of-line (EOL) packaging. Increasingly, manufacturers and contract packagers look for flexibility in the equipment they specify for their packaging lines. The impetus for this is two-fold. First, manufactures are looking to do more with less — more productivity and more uptime, with fewer personnel, less floor space and less capital equipment. Robotic case packers and palletizers offer a higher rate of speed than most traditional EOL systems, and fewer personnel are required to operate the equipment. A carefully designed robotic system will also greatly reduce the amount of floor space required for the system, especially in multi-SKU lines where conveyors require a substantial portion of the needed floor space.

Second, retailers who are in the process of streamlining their own operations have started to require manufactures to deliver mixed pallets — pallet loads that consist of multiple products in various case sizes. Robotic case packers and palletizers handle changes in package size and weight more efficiently, and robotic EOAT can be designed to handle multiple product types. Even EOAT dedicated to a single product can increase flexibility as changeovers require no tools and can be accomplished in under two minutes. Automatic EOAT changeover systems, such as the one available from ESS Technologies, make fast changeover even easier, and completely hands-free. Responding to pre-programmed instructions, the robot detaches one EOAT to a special docking station that holds all the EOAT for the system. Once docked, the robot automatically releases the current EOAT and positions itself over the desired EOAT. The robot then connects itself to the selected EOAT and returns to the ready position. Today’s robotic controllers allow multiple “recipes” to be stored, making the switch from one product to another a simple “one-button” process.


Robotic case packers and palletizers offer a more flexible and reliable solution for packaging products from single or multiple packaging lines. The low maintenance costs and ease of operation give robotic systems a very fast return on investment (ROI), and their flexibility and high reliability make them useful for many years as they tackle the packaging challenges that non-robotic systems cannot address.