No two production lines are identical. That is why a custom automation cell is not selected from a catalog. It is engineered around the customer's exact product, footprint, and throughput target.
As a FANUC Authorized System Integrator, Odecopack USA builds these cells through a repeatable process. Regardless of the industry or the product being handled, a custom robotic cell typically moves through the same five stages between the first conversation and the day it starts running product.
1. Concept & CAD Design
Every project starts with gathering the details that shape the design: product dimensions and weight, packaging format, required cycle time, available floor space, and how the cell needs to connect to the equipment already running upstream and downstream.
That information is translated into a 3D model before fabrication begins. Working in CAD at this stage makes it possible to validate:
- Robot reach and achievable cycle time.
- Product infeed and outfeed flow.
- Safety perimeter, fencing and guarding placement.
- Floor space and utility routing (power, air, network).
- Integration points with existing conveyors and equipment.
Reviewing the model with the customer before fabrication begins is one of the most effective ways to catch layout conflicts and avoid costly changes later in the project.
2. End-of-Arm Tooling (EOAT) Design
The tool mounted to the end of a robot's arm, known as the EOAT, determines whether a robot can reliably handle a given product. It is rarely off the shelf.
EOAT design depends on the specific characteristics of the product being handled, including:
- Product weight and center of gravity.
- Surface material, such as a rigid case, film-wrapped tray, flexible pouch, or bottle.
- Fragility and required grip force.
- Number of items to be picked per cycle.
- Available approach angle within the cell.
Depending on those factors, tooling may combine vacuum cups, mechanical fingers, servo-actuated clamps, or a hybrid of the three. The gripper is modeled alongside the robot in CAD, then built and tested against samples of the actual product before it is trusted on the line.
3. Control Panel Assembly
While the mechanical structure is being built, the control panel is assembled in parallel. It is the electrical backbone of the cell, where every drive, sensor, and safety device in the system reports back.
A typical panel for a custom cell includes:
- Circuit breakers and motor protection.
- Variable frequency or servo drives.
- Safety relays and safety-rated I/O.
- PLC and network switches.
- HMI touchscreen for operator interaction.
Panels are wired and labeled to a consistent standard so maintenance technicians from Odecopack or the customer's own team can troubleshoot the system quickly throughout the equipment's life.
4. PLC Programming & Controls Integration
With the panel built, the logic that runs the cell is programmed and tested. Odecopack's platform of choice for this work is Omron's NX control architecture, connected over EtherNet/IP with Safety over EtherCAT for safety I/O.
This stage of the project covers:
- I/O mapping between the robot, sensors and actuators.
- HMI screen design for operators and recipe changeover.
- Safety zone logic tied to fencing, light curtains and e-stops.
- Communication with upstream and downstream equipment PLCs.
- Alarm and diagnostic logic to speed up troubleshooting.
5. Application Testing & Commissioning
Before the cell ever leaves the shop, it is run against the customer's real product, not a placeholder box.
This is where cycle times, grip reliability and pallet or case patterns are fine-tuned. Any adjustments to tooling or programming are far less costly to make here than after the equipment has shipped.
For most projects, this stage includes a formal Factory Acceptance Test with the customer before the cell is disassembled for shipping.
FAT means Factory Acceptance Test. It is the process used to test and validate the equipment at the manufacturer's facility before it is shipped and installed at the customer's location.
Once on-site, the cell is reassembled, integrated into the existing line, and commissioned. This includes safety validation, final cycle time confirmation, and operator training before production handover.
Why a Staged Process Matters
Following the same five stages on every project, rather than skipping ahead to fabrication, keeps custom automation predictable. It typically results in:
- Fewer surprises during the Factory Acceptance Test.
- Shorter on-site commissioning windows.
- Tooling and controls proven before the equipment ever ships.
- A clear, documented reference point if the line is expanded later.
- A more predictable project budget and timeline.
Conclusion
A custom robotic cell is only as good as the process used to build it. From the first CAD layout through EOAT design, panel building, controls integration and final commissioning, each stage exists to catch problems while they are still inexpensive to fix.
As a FANUC Authorized System Integrator with decades of packaging automation experience, Odecopack USA applies this same process to robotic integration, EOAT design, PLC integration, safety retrofits, control panel assembly, motion control applications, and vision systems. Each project is scoped to the product and process in front of us, from concept to commissioning under one contract.