Tel: 01223 499488
Have you seen our new Robotic Palletiser video?
Click here to find out more about the Granta GA15 palletising system.
Follow this link to book your free assessment visit https://www.granta-automation.co.uk/types-of-automation/robotic-palletising
Watch automation videos…
In the fast paced environment that we now live in, things are changing all the time. Products change: sizes, quantities, types, weights, material. With the breadth of knowledge and range of materials now available to us products evolve and change far quicker than they ever have done before. You may design a new product and then find that due to the fast pace of product development, in less than a year, you need to alter or change your product in some way to keep abreast of market developments.
This can have its challenges as we all know! Production processes have to change, packing processes have to change, and production speeds may well have to change as well. All this has cost implications which have to be weighed up against the enhanced value of the new product to decide if the change is financially viable.
Often the cost of making these production and packaging changes make it unviable to enhance your product, and you miss the opportunity to realise the value of selling an enhanced product and becoming an industry leader. This is the type of conundrum that manufacturers are faced with day after day. If I modify my product will I ever realise the value of my capital investment in the production process during the lifetime of the product? But, all this is about to change…
Here’s the good news! We have developed an incredibly innovative palletiser. It’s as flexible and adaptable as your production process needs to be to keep up with market demands. If your product size increases, a quick touch of the button and the palletiser is ready to go. If you want to stack more products per pallet, another quick touch of the button and it’s ready to go. There has never before been so much adaptability in a palletising system.
What if I stop making a product you ask… We’ve considered for that as well. Simply unbolt the palletiser and use your forklift to transfer the system to another production process in your factory. In less than a day the palletising system will be up and running on your new line, leaving nothing in the old location other than 4 bolt holes where the robot was once bolted to the floor.
Still not sure about all this? Then try before you buy. We’ve developed our free trial scheme to give you the opportunity to see how your product would work on the GA15 palletising series before you commit to investing capital in the system. There’s two ways of doing this, either send us your product to try on the palletiser before you buy, or visit Granta with your product to see how it works on the palletiser.
Want to book up your free trial? Let us know at helpline@granta-automation.co.uk or give us a call on 01223 499488.
Watch automation videos…
In the world of manufacturing, the thought of changing from one method of working to something new can raise a number of concerns. Businesses become reliant on established procedures, even if they know they could be improved by implementing new ideas. That is certainly the case for many when it comes to the idea of installing automation.
There are a number of misconceptions about automation and the way it will impact manufacturing operations. From loss of jobs to the financial implications, it can make some business owners cautious about investing in automation. However, once installed, they quickly discover that the reality of the technology is vastly different to their original expectations. We cover the main concerns held by business owners below whilst highlighting the positive ways it will add value to your production process.
Expectations: Perceived View of Automation
The idea of using automation can bring with it some negative pre-conceptions about its impact. Some of this can be down to the way it has been perceived outside of specialists industries, with fears that the technology will dramatically change the entire business model: Some of these concerns include:
Reality: Actual Outcomes of Installing Automation
Whilst there is understandably some uncertainty about automation before investing in the technology, what businesses quickly discover is a vastly different reality compared to their initial expectations. This include things such as:
In conclusion, whilst there will always be many different aspects to consider when investigating the case for installing automation in your business, if you have used a comprehensive Automation Payback Calculator to accurately calculate the project payback, you will be able to quickly see if there is a business case for investment.
Watch automation videos…
This video of a Bag Palletising Robot from Granta will give you an idea of what Automated Bag Palletising looks like in action!
More information on our Robotic Palletising Systems is available here.
Watch automation videos…
Every day in the UK there are millions of pallets being stacked with a wide variety of products. Estimates suggest that as much as 50-60% of this process is undertaken by hand. This is yet another reflection of how far behind the UK currently is in terms of adopting automation and robotics, and in many cases people are unaware of the current technologies available that could add tangible benefits to their business.
To help you get a clearer understanding, we have put together this article as an introduction to automated pallet stacking and the key things to consider if you are thinking about investing in automation.
What is palletising?
Palletising is the process of placing or stacking goods onto a pallet or pallets.
Over the years palletising has developed from being entirely reliant on manual labour, to the introduction of automated machinery to place products onto pallets in preparation for their despatch. Efficient palletising of products is an essential part of the supply chain as it ensures the production process is leaner and more efficient. Automated palletising systems can also be designed to include the dispensing of slip sheets onto the pallet, either in-between the various product layers, or on top of the finished load.
Automatic pallet feeding can also be included in a robotic palletising system. Automated pallet feeding works in tandem with the production to keep the production line running continuously.
What are the advantages of automated pallet stacking?
Typical payback calculation for an automated pallet stacking system
Click here to download our excel payback calculator with typical payback calculations, enter your full production details to see what the payback could be for you.
Risks of using automation and how to overcome them
Conclusion
Introducing automatic pallet stacking into your facility will dramatically improve the efficiency of your production line thanks to the many benefits it brings. In the vast majority of cases this can be felt with immediate effect, ensuring you see a tangible return on investment which enables you to recoup your outlay in a relatively short space of time.
Whilst there can be some initial challenges to overcome, this can be effectively managed by choosing a specialist automation company that will work with you to find a solution that matches your needs.
Try your products on a palletiser for FREE, book now!
Watch automation videos…
Quality control in a manufacturing environment is one of the most vital areas of the production process and its value can never be underestimated. Manually inspecting products is still a popular choice for many companies today and while it has some advantages, the downsides can prove to be hugely problematic.
In most cases this is due to mental fatigue of staff whose concentration levels naturally decline after an hour or two. The question is, why does this happen and what can be done to rectify it? Our blog digs a little deeper to find out more about the study of human concentration, the history behind a term referred to in psychology as vigilance decrement, and how it affects the manufacturing process.
What is vigilance decrement?
The term vigilance is used in the context of sustained concentration, meaning being able to sustain concentrated attention for long periods of time. A study focused on human vigilance was conducted during the Second World War by Norman Mackworth, a renowned British psychologist and cognitive scientist.
His 1948 paper ‘The breakdown of vigilance during prolonged visual search’ has since gone on to become the most influential publication about human vigilance. His study was centred on the mistakes made by radar and sonar operators towards the end of their shifts.
To understand why this occurred he used a test method that eventually became known as the Mackworth Clock. He discovered that operators experienced a decline in signal detection the longer they were asked to concentrate, an event now referred to as vigilance decrement.
Those who took part in the experiments were noted as losing between 10-15% of their concentration ability within the first 30 minutes of a two-hour period, and it continued to gradually decline over the remaining 90 minutes.
Graphs showing the downs and ups of vigilance. The vigilance decrement as a decline in signal detection over time or an increase in response time to correct detections over time.
Reference: Vigilance, workload, and stress – Scientific Figure on ResearchGate. Available from: https://www.researchgate.net/The-downs-and-ups-of-vigilance-The-vigilance-decrement-as-a-decline-in-signal-detection_fig1_286031710 [accessed 20 Aug, 2018]
How might vigilance decrement affect your business?
Even in today’s technologically advanced manufacturing world there are still a large number of companies who rely on traditional manual methods in their factories. This is particularly true when talking about product inspection and quality control. Sometimes it may simply be a case of preference, or lack of budget. In many cases it is believed that manual quality control is the most accurate way to ensure goods are made to standard, with a premium price often paid to keep this manual process in place.
Norman Mackworth’s study on vigilance decrement focused on radar and sonar operators but the idea is transferable to any activity requiring long periods of concentration. In an age where mobile phones and digital devices are touted as being responsible for our shortening attention span, the results of Mackworth’s research is possibly more relevant than ever.
Staff members who are given the task of manual quality control will naturally experience a fall in levels of concentration the longer they are doing it. This will invariably mean quality control standards will also dip during this same period, allowing sub-par products to slip through the net. There is still a chance these mistakes can be identified before the goods reach consumers, but if not, this could lead to expensive returns and recalls and ultimately a loss in public confidence.
What can you do to reduce the effects of vigilance decrement?
The good news is you will be able to implement some measures that can help avoid some of the damaging aspects of vigilance decrement. What should be remembered though is that this will not eliminate the issue completely and will require close monitoring, intricate scheduling and potentially higher on-going costs.
How do I eliminate the vigilance decrement effect?
While there are ways to reduce the effects created by low levels of concentration during manual product inspections, it cannot be removed completely. Mistakes are an inherent part of our human make-up and while there are some positives to be gained from that in terms of learning from our errors, in a manufacturing environment it usually equates to loss of valuable time and money.
This is where automated machinery holds a big advantage, inspecting products at a faster rate without being affected by vigilance decrement even after hours of repeating the same process.
A perfect example would be vision inspection systems which are used to significantly improve quality control. These automated inspection systems use either standard 2D cameras or 3D laser line scanners. This enables manufacturers to check and read product labels, measure the size and shape of objects to ensure each one is at the correct dimension, inspect for marks or scratches and much more.
Understanding which machine vision system is right for you may require a little assistance, but regardless of the scale of operation or type of product there is one available that will ensure your quality control is significantly improved.
Watch automation videos…
When calculating payback with automation it is easy to think that payback is equal to the number of staff wages saved by the automation multiplied by the annual staff salary, but this is rarely correct. Calculating the payback on an automation project is often more difficult and involved than people imagine. There are many factors to consider including:
To help you pull it all together we have created a simple excel payback calculator which you can download for FREE. This asks all the key questions needed to calculate payback and then gives you several statistics to help you with your business decisions in relation to automation. It also has a finance offer, so once you have completed the form, the second tab has a finance scheme offer from our leasing provider Tower Leasing.
Find out now! Download the payback calculator using the form below.
If you have any questions or difficulties filling it in, feel free to contact us on 01223 499488 and we will be glad to help.
We also have a free downloadable robotics and automation pack available. This pack includes many other useful calculators including an intangible benefits calculator.
The debate around Brexit continues to intensify as not only the UK, but also our trading partners across the world, patiently await definitive announcements regarding our exit from the EU. The big question on the lips of all manufacturers is how will Brexit affect manufacturers in the UK?
At Granta Automation we remain cautiously optimistic about its effect on the sector and the economy as a whole and below we look into the current state of manufacturing and how things might develop over the next 12 to 18 months.
A positive end to 2017
Manufacturing in the UK experienced an unexpected upturn throughout most of 2017, ending on a largely positive note, with the average between October and December 2017 the highest seen in the industry for almost ten years. However, there is still an air of uncertainty surrounding the long term effects of Brexit and how it will directly impact on the manufacturing sector.
As it currently stands, manufacturing makes up approximately 10% of the UK economy although this doesn’t take into account the many trades and jobs that support – and are supported by – the industry. How Brexit will impact on these industries is unknown and the ripple effect created through these associated industries could prove problematic.
British goods retain their value
Although 2017 ended on a high note, the economy has slowed down somewhat at the start of 2018. The first quarter saw growth drop to 0.4%, an 8 month low that is in stark contrast to the rise in production seen the previous year. Since the Brexit results were announced in June 2016 it is the second lowest reading, despite output remaining above 50 on the purchasing manager’s index.
With the pound starting to regain its strength British products are more expensive compared to previous years. Although, a new report by Barclays in February highlighted that overseas consumers were willing to pay up to 22% more for British food goods. This also translates across to other industries such as automotive (10%), alcohol (9%) and clothes (9%) with consumers prepared to pay premium prices for products that are labelled as British made.
Areas of concern
Not every study offers such good news, however. Based on the current models of Brexit currently under consideration by the government there are concerns that British manufacturing exports could be reduced by a third, as detailed by the UK Trade Policy Observatory in their paper released earlier this year.
Their analysis was based on leaked estimates from the Treasury, building a more comprehensive model to assess the impact on 122 manufacturing sectors. They suggest that areas such as Sunderland, Coventry, Derby and Birmingham could be amongst those worst affected by the current Brexit plans. Taking into account increases to other domestic industries their final estimation was a total reduction in manufacturing output of 3.6%, with carmakers facing the biggest uphill struggle. The aerospace and pharmaceutical manufacturing sectors were also singled out as being particularly hard hit.
2018 and onwards
The collapse of Carillion at the start of the year may have put many other firms on edge about the coming 12-24 months, however, it should not be forgotten that the problems the construction giant struggled to overcome were far more complicated than simply being related to Brexit. It should also be remembered that optimism in the manufacturing sector was high at the start of the year, as illustrated by manufacturers organisation, EEF’s report which saw many business anticipating more productivity in 2018.
Industry 4.0, or smart manufacturing as it is also known, also holds significant opportunities for manufacturing companies, along with increased investment in automation and robotics and further integration of Internet of Things (IoT).
Of course, the analysis so far is based on hypothetical studies and research, using concepts and plans that are far from set in stone. Every week seems to bring a new development as disagreements continue between the Houses of Parliament, the House of Lords, the Irish government and the European Union themselves.
The uncertainty is unsettling to the business community as a whole and isn’t exclusive to the manufacturing sector, but until discussions are complete, decisions are made and new policies implemented, there is no sure fire way of knowing how the economy will be effected in the long run. The good news is that despite the lack of clarity the manufacturing sector continues to evolve and move forward and there are still a lot of exciting developments we can all look forward to over the coming months.
To find out how we can help you keep pace with the changing face of manufacturing in the UK, contact our automation consultants who are always on hand to quickly respond to your questions, and provide detailed answers based on your current automated palletising requirements. They can be contacted on 01223 499488, or via email at helpline@granta-automation.co.uk
Watch automation videos…
Brief
Granta were asked by a medium sized food factory to look at ways of improving their current manual bag stacking process. They were packing dry, free-flowing, granular product into 25kg bags and then manually stacking the filled bags onto pallets at the end of the production line.
They had been having complaints from staff in relation to back pain due to lifting and stacking the 25kg bags all day. There were also other issues with manually stacking the bags onto pallets:
With the need to increase production speeds and address the health and safety issues they were experiencing, they requested Granta to come up with a solution.
The Solution
We carried out an on-site assessment of the existing process so that we fully understood the customer’s requirements. During this assessment we realised that there was an added challenge to automating the palletising process: once the bag had been laid down after the mouth of the bag had been stitched, we would then need to redistribute the product within the bag, prior to stacking it on the pallet. We knew that flat bags were going to play a key part in achieving a neatly and safely stacked pallet.
Following our site visit, our automation consultants held a brainstorming session to come up with the best automation solution for this company. We explored ideas and methods and discussed these with our customer and collaboratively came up with the following solution.
We designed, built and installed a bespoke robotic palletising cell for the end of their production line which included:
The solution proved to be very successful and gave the food company an increased production throughput of 150%!
The Sequel
With the installed automation having been so successful the customer asked us to replicate the same system on two more of their manual bagging lines. Our automation consultants reviewed the palletiser system we had installed and came up with a scheme of using one robot to serve the additional two lines rather than having to install two separate robots. This would save the customer cost and space.
Following consultation with the customer, we designed, built and installed the following system;
The Final Outcome?
A very happy customer that has increased their production throughput significantly and improved health and safety in their workplace by reducing the risk of repetitive strain injuries.
Watch automation videos…
The success of the manufacturing sector relies on constant evolution of the processes involved, utilising new equipment, technology and techniques to find optimal efficiency gains. The exponential growth of technology, in particular, remains as true today as it did 50 years ago and the production landscape is changing shape faster than ever before.
Keeping pace with developments allows your business to remain a constant and relevant force in the market place. With that in mind, we’ve listed what we believe to be the key trends in the manufacturing industry and what you need to focus on for your manufacturing plant in 2018/19.
The Internet of Things (IoT)
The need to increase efficiency, reduce costs, improve safety and incentivise product innovation are just some of the challenges facing manufacturers who are considering implementing the Internet of Things into their operations.
IoT enabled equipment will allow manufacturers to maximise the lifespan of their technology without disturbing the output. With lower levels of maintenance planning, equipment downtime and maintenance costs, it provides a number of essential advantages in an increasingly competitive market.
Enhanced connectivity will dramatically change how manufacturers capture and use key data. In turn this will provide stronger insights into the supply chain and inventory processes. Optimising production in real-time will enable businesses to become more efficient and limit wastage output.
Industry 4.0
Otherwise known as smart manufacturing, Industry 4.0 has been labelled as the 4th industrial revolution. The use of advanced manufacturing technology right across the production chain provides vast improvements on processes, enhancing efficiency and making the factory floor safer for employees. The ability to monitor and analyse assets more closely ensures it is possible to constantly tweak and evolve the level of output.
The implementation of Industry 4.0 provides a number of advantages for manufacturers, including increased productivity, faster reaction times to customers, the creation of new services and product lines, as well as improved delivery to market. With the right framework in place and the critical business areas addressed, smart manufacturing opens up extensive and exciting new possibilities across almost every sector.
Cobot Manufacturing
Collaborative robots are already in place in a number of factories in a wide number of industries. However, technology never stands still and the evolution of these robots means lightweight and agile versions are set to become more common place in the manufacturing sector.
Cobots are being designed to be more sensitive to respond to human interaction and reduce the level of risk involved in working more closely together. For example, built in sensors can detect the presence of a human and reduce the operating speed the closer the human gets to the machine. Cobot’s can also control the speed and force being applied and instantly stop when an obstacle is encountered, significantly lowering the impact density.
Augmented reality
While virtual reality has made great strides in the past decade, experts have always felt that augmented reality offered even greater opportunities. The blending together of the real world with advanced computer generated visual aids may still be in its early stages but interest from the manufacturing sector is rapidly gaining pace.
For example, the use of wearable technologies connects workers to a goldmine of information and data to help optimise job performance while increasing safety. AR could be implemented on assembly lines, skilled training, maintenance, support services, quality assurance and automation.
At one time this sort of technology may have seemed light years away from being used in real time environments. This is no longer the case with AR actually in use in a number of facilities right now. As the technology improves exponentially, so will the myriad of ways it will improve the manufacturing sector.
Additive manufacturing
The use of 3D printing technology is becoming more common place, helping to introduce efficient and cost effective practices. Additive manufacturing allows for the prototyping, tooling – and on occasion – the production of applications used within the manufacturing process.
3D printing enables manufacturers to reduce the large inventories of spare parts required to respond quickly to customer orders. By being able to produce the part without large stock levels adding to their storage space costs, response times are maintained, while being more cost effective and maintaining the integrity of the equipment supplied.
Using additive manufacturing processes to create prototypes and tooling moulds increases operational efficiency while also lowering costs. Rather than running up huge costs and taking months to produce, 3D printing enables this to be produced within a matter of days.
To find out how we can help you keep pace with the latest automated palletising solutions for your facility, contact our automation consultants who are always on hand to quickly respond to your questions, and provide detailed answers based on your current requirements. They can be contacted on 01223 499488, or via email at helpline@granta-automation.co.uk .
Watch automation videos…
