Key Aspects and Best Practices to Prepare for New End-of-Line Automation

Automating the end of a production line is a significant investment that can:

• Enhance operational efficiency.
• Improve product quality.
• Reduce labor costs.
• Increase production consistency.

However, if important topics are not properly addressed before implementing an automated end-of-line solution, several issues may arise during the implementation phase, including:

• Overspending.
• Considerable project delays.
• Reduced efficiency.
• Difficulty adapting the system to end-user needs.

Receiving a new piece of automation equipment is exciting, especially after a long planning and engineering process. However, businesses and project engineers should evaluate several key factors before committing to the installation.

These considerations help ensure:

• A smooth transition.
• Successful equipment commissioning.
• Better operator adoption.
• Reduced downtime.
• Long-term project success.

Based on Odecopack's experience, the following aspects are commonly overlooked but play a crucial role in the success of an automation project.

1. Trained and Capable Staff

Even the most advanced automation solutions require skilled personnel to operate, manage, and maintain them.

Training should be included as part of the project delivery scope for:

• Daily equipment operators.
• Maintenance technicians.
• Engineering-level personnel.
• Production supervisors.

A recommended practice is to involve operators during the conceptualization and engineering phases of the project.

Operators have valuable knowledge about:

• Common production issues.
• Product characteristics.
• Packaging difficulties.
• Existing operational limitations.
• Daily workflow requirements.

Including operators early in the project provides them with a better understanding of:

• System functionality.
• Key operational aspects.
• Troubleshooting procedures.
• Equipment capabilities and limitations.

This proactive approach can lead to:

• Better system performance.
• Faster operator adoption.
• Reduced training time.
• Less equipment downtime.

2. Upstream Process Quality Control

Automation performs best when the incoming product is consistent and meets established quality standards.

This is one of the most overlooked aspects when companies transition from manual operations to automated systems.

Manual operations provide workers with a high level of flexibility and adaptability. Human operators can inspect products using their vision, touch, experience, and judgment while performing packaging tasks.

Because of this flexibility, certain product or process conditions may not have been previously identified or corrected.

Potential upstream issues include:

• Inconsistent product dimensions.
• Product defects.
• Incorrect product orientation.
• Variations in weight or shape.
• Damaged products.
• Inconsistent product spacing.
• Irregular incoming product flow.

Some products and industries require inspection before secondary packaging. In manual processes, this inspection is often performed by human packers who can multitask and identify defects using their eyes and hands.

Modern automated systems can perform effective quality inspections using technologies such as:

• Vision systems.
• Sensors.
• Product detection systems.
• Measurement devices.
• Automated rejection mechanisms.

These technologies can provide reliable inspection without adding excessive complexity or cost, making automated packaging projects more feasible.

3. Safety Concerns and Requirements

End-of-line automation must comply with applicable workplace safety regulations.

Typical safety measures include:

• Safety fencing.
• Safety doors and interlocks.
• Emergency stop mechanisms.
• Light curtains.
• Safety sensors.
• Safe access points.
• Lockout and tagout procedures.
• Employee safety training.

During the system design and dimensioning process, end users and customers must determine their required safety standards.

They should also communicate any specific safety concerns to the system provider.

This helps reduce the risk of:

• Employee injuries.
• Fatal accidents.
• Equipment damage.
• Unexpected project modifications.
• Regulatory noncompliance.
• Costly implementation delays.

An experienced system integrator should guide the customer in determining the appropriate PLr, or Required Performance Level, based on:

• Customer expectations.
• Equipment functionality.
• Identified hazards.
• Operational risks.
• Employee interaction with the system.

Establishing these requirements early gives both the customer and the system integrator a clear roadmap for the safety system's design and expected performance.

Failing to establish a baseline for safety standards can result in:

• Expensive project delays.
• Additional engineering work.
• Equipment modifications.
• Safety compliance issues.
• Injuries or fatalities.

4. Packaging Materials and Required Adjustments

Automated packaging solutions may require adjustments to existing packaging materials.

Packaging components must be compatible with the automation system, including:

• Boxes.
• Cartons.
• Trays.
• Films.
• Labels.
• Adhesives.
• Dividers.
• Protective inserts.
• Other packaging materials.

Incompatible packaging materials can cause:

• Product jams.
• Misaligned packages.
• Failed box forming.
• Improper sealing.
• Production interruptions.
• Reduced system efficiency.
• Increased material waste.

A recommended practice is to involve packaging engineers and packaging material vendors during the engineering phase.

This collaboration makes it easier to:

• Identify packaging limitations.
• Review material tolerances.
• Test packaging performance.
• Modify box or tray designs.
• Select compatible materials.
• Make adjustments before equipment installation.

Addressing these factors early can prevent:

• Efficiency losses.
• Long and frustrating FAT procedures.
• Extended commissioning periods.
• Unexpected packaging redesigns.

5. Throughput and Efficiency Expectations

Businesses should define clear production goals before selecting or designing an automation system.

The system must align with the required throughput and production rates.

Important factors to evaluate include:

• Required products per minute.
• Machine cycle times.
• Line speed.
• Product changeover times.
• Planned production hours.
• Equipment availability.
• Upstream and downstream bottlenecks.
• Peak production demands.
• Scheduled maintenance.
• Expected downtime.

Production expectations should be realistic and measurable.

The automation system should not be evaluated only by its maximum theoretical speed. Its expected real-world performance must also consider:

• Product variability.
• Operator intervention.
• Material quality.
• Product changeovers.
• Maintenance requirements.
• Upstream equipment performance.
• Downstream equipment capacity.

6. Growth Planning and Overhead Capacity

Automation investments should consider future business growth, not only current production requirements.

The system should provide sufficient flexibility and scalability to support:

• Increased production volumes.
• New product formats.
• New product lines.
• Additional shifts.
• New packaging configurations.
• Additional automation modules.
• Future equipment integration.

Planning for overhead capacity can prevent the automation system from becoming obsolete or insufficient shortly after installation.

A scalable system may include:

• Modular equipment.
• Expandable conveyor layouts.
• Additional robot capacity.
• Flexible programming.
• Adjustable tooling.
• Space for future equipment.
• Communication capabilities for additional systems.

Conclusion

By addressing these key aspects, businesses can better prepare for the successful implementation of end-of-line automation.

Proper planning helps ensure:

• Seamless system integration.
• Improved operational efficiency.
• Better employee adoption.
• Reduced implementation risks.
• Lower downtime.
• Long-term productivity gains.

Having an experienced automation partner such as Odecopack can be essential when selecting equipment and identifying the adjustments required within the production process.

An experienced partner can help customers:

• Select the appropriate equipment.
• Evaluate existing production processes.
• Identify potential automation risks.
• Define safety requirements.
• Review packaging compatibility.
• Establish realistic performance expectations.
• Prepare the operation for future growth.

This expertise is especially valuable when navigating the complexities of automation and working toward optimal efficiency and equipment performance.