Automation Solutions
72%
Reduction in labor
This project transitioned a labor-intensive manual process, combining two metal brackets with an injection-molded part using two screws, into a fully automated solution. By boosting efficiency, we reduced operator workload and redirected that capacity toward managing new automated systems.
2x
Production output, 87% less WIP
Optimized production by installing a conveyor system to link two injection molding machines to one automation unit, reducing idle time and boosting overall equipment effectiveness (OEE). The design enables precise control of parts arriving from both injection molding machines to prevent jams. It also allows the machines to continue placing parts on the conveyor during automation downtime, which eliminated 87% of the Work-In-Progress (WIP) that previously accumulated in Gaylords.
28%
Production increase, 5-month payback
Mitigated a process bottleneck with the use of an Epson robot, achieving a 0.8-second cycle time reduction per part and a 205-part increase in hourly yield. The design increased production capacity and achieved a five-month payback period, making the project as financially viable as it was operationally efficient. Hourly uptime also increased by 8% by eliminating parts jamming on incoming conveyors.
<1 sec
Per part, 21 printers integrated
By quickly and efficiently integrating 21 Keyence inkjet printers into existing production lines, we bypassed ongoing supply chain issues. Beyond resolving these logistical hurdles, the transition to direct printing significantly reduced the per-unit cost of barcodes compared to traditional paper labels, and eliminated the maintenance costs associated with the legacy labeling systems.
$475k
Savings with minimal investment
By installing mechanical gating devices and optimizing the control logic of the existing conveyor system, we enabled four injection molding machines to maintain continuous operation during downstream automation outages. The solution leveraged existing PLC infrastructure with minimal capital investment to drastically reduce WIP accumulation. Previously, all four machines were idled daily due to excessive WIP; after implementation, these shutdowns were reduced to one or two occurrences per week, vastly improving total system uptime and cost-efficiency.
100%
Inspection compliance maintained
Implemented an in-line vision system to automatically distinguish conforming and non-conforming parts within the automation cell, eliminating the need for offline inspection. Maintained 100% inspection compliance while significantly reducing operator labor per shift and improving overall process efficiency.
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