Building the future: Addressing challenges with industrial and collaborative robotics in plastics manufacturing

The plastics industry faces significant challenges in maintaining competitiveness in the market. Some of these challenges can be effectively addressed through the integration of industrial and collaborative robotics. This article explores the main issues and future prospects for operations management in this dynamic sector, focusing on how robotics is reshaping manufacturing processes to meet these challenges head-on.

In the hectic environment of a plastic manufacturing plant, maintaining smooth production without interruptions is a monumental task. For instance, if a machine breaks down or an operator calls in sick, the entire production line can face delays, affecting the plant’s ability to meet delivery deadlines. This is where industrial robots shine. Capable of working tirelessly around the clock, robots ensure a consistent production rate, minimizing interruptions. For example, the integration of robot arms that handle repetitive tasks like moving molds parts between processing stations can prevent time wastage and enable a faster production turnover, directly addressing inefficiencies and enhancing workflow.

The scarcity of skilled labor in the industry is another significant obstacle. Consider a scenario where a high-demand order is received, but the plant is understaffed due to a lack of qualified workers. Training new employees in time-sensitive situations may not always be viable. Robots can fill these gaps by taking over repetitive and hazardous tasks, such as handling hot plastic parts straight from the injection molding machines. This frees up human workers to engage in more value-added activities like process optimization and creative problem-solving. Imagine a collaborative robot (cobot) working alongside operators to manage material handling, effectively creating a partnership that maximizes human talent while the robots handle drudgery.

Ensuring that every product meets exacting quality standards can be a daunting challenge with human operators, especially over long shifts where fatigue sets in. For example, manual quality inspections can miss minute defects, leading to inconsistent product batches. Robotic systems bring unparalleled precision and consistency to the table. Industrial robots equipped with advanced vision systems can conduct detailed, real-time quality checks during the manufacturing process. For instance, a robot can monitor injection molding processes and immediately identify defects, ensuring that only top-quality products proceed to the next production stage. This level of accuracy not only reduces waste and rework but also ensures that you consistently deliver high-quality products to your clients.

The risk of injury in plastics manufacturing is a significant concern, with workers often exposed to high temperatures, sharp objects, and heavy machinery. For example, operators manually loading and unloading parts or inserts in injection molding machines can result in severe injuries. By deploying robots to handle dangerous and physically demanding tasks, these risks can be dramatically reduced. Robots can autonomously manage the loading and unloading of parts from hot molding machines, ensuring human operators remain safe and focusing on oversight roles rather than direct physical involvement. This transition not only enhances workplace safety but also reduces costs associated with medical leaves and accident claims.

Unanticipated equipment breakdowns can halt an entire production line, consequently leading to expensive downtimes. Suppose a critical molding machine fails during peak production hours; the delays can be costly and disruptive. With robotics, predictive maintenance becomes feasible. Robots fitted with IoT sensors can continuously monitor machine health, predicting and alerting maintenance teams about potential failures before they occur. This enables timely interventions to prevent breakdowns. Additionally, robotic machines themselves are designed with high reliability and minimal maintenance needs, further reducing operational disruptions.

The integration of robotics into plastics manufacturing is revolutionizing production lines by enhancing efficiency, consistency, and safety. Robots can be employed in various stages of the production process, from machine tending to post-processing, offering significant improvements in productivity and quality. 

• Machine tending: Robots can load and unload injection molding machines, reducing the risk of injuries to workers and improving production consistency.
• Insert molding: Robots can efficiently handle tasks like adding inserts to moldings and loading them into machines.They are faster, which reduces cycle times and increases profitability.
• Overmolding: Six-axis robots can automate the overmolding process, reducing labor and assembly expenses while ensuring product quality.They also speed up production, lowering cycle times and boosting profitability.
• In-mold labeling: Robots can perform precise in-mold labeling, enhancing the efficiency and accuracy of this process.
• Post-processing: Robots can handle various post-processing tasks such as inspection, testing, and hot-stamping of plastic molded parts.

Initial need:

A global Tier 1 supplier in the automotive industry approached our DIY Official Integrator and sought to optimize their overmolding process, specifically involving the overmolding of a plastic insert with EPDM. The client’s existing setup required 12 operators to meet the cycle times and annual production volumes.

The customer needed to maintain precise cuts on a lip with a few thousandths of an inch tolerance. This task required a level of craftsmanship that was difficult to sustain consistently and efficiently with manual labor. The goal was to reduce the reliance on a large number of operators while achieving the required precision and improving overall efficiency.

Challenges:

1. Production delays and inefficiencies: The reliance on 12 operators led to frequent delays due to manual errors and the need for meticulous precision, which slowed down the production process.
2. Workforce constraints and skill Shortages: High turnover rates and the need for constant recruitment and training of skilled operators were costly and time-consuming.
3. Maintaining quality and consistency: Manual cutting struggled to consistently meet the required precision, leading to quality issues and inconsistent product batches.
4. Safety and workplace injuries: Operators handling knives faced significant risks of injuries, contributing to higher medical costs and lost workdays.
5. Unplanned downtime and maintenance challenges: The manual nature of the process led to frequent unplanned downtime due to operator fatigue and equipment maintenance issues.

Solution:

Our Official Integrator implemented a solution using two Comet 44 robotic cells equipped with laser cutting technology. This automated the precise cutting task, significantly reducing the need for manual intervention.

Results:

1. Optimizing production efficiency and timeliness: The automation of the cutting process with robotic cells eliminated manual errors and significantly reduced cycle times, leading to a smoother and more efficient production flow.
2. Empowering workforce and enhancing skills: The implementation of robotic cells reduced the need for 6 operators, minimizing the challenges associated with high turnover rates, recruitment, and training costs.
3. Ensuring high quality and consistency: The laser cutting robots provided unparalleled precision and repeatability, achieving an Overall Equipment Effectiveness (OEE) of 98%. The quality level, previously unattainable with manual labor, was consistently met.
4. Promoting workplace safety and well-being: With robots handling the cutting tasks, operators no longer need to use knives, significantly reducing the risk of injuries and musculoskeletal issues.
5. Maximizing uptime and streamlining maintenance: The reliable performance of the robotic cells minimized unplanned downtime and reduced maintenance challenges, ensuring continuous production.

Financial impact:

The initial investment of $300,000 USD for 2 laser robotic trimming cells resulted in an estimated savings of $900,000 USD over three years. This substantial return on investment was achieved through reduced labor costs, improved quality, and enhanced operational efficiency.

The integration of industrial and collaborative robotics in the plastics industry offers significant opportunities for improving efficiency, quality, and competitiveness. However, it also presents challenges that operations managers must address, including initial investment costs, workforce adaptation, and ongoing maintenance.

As the robotics market continues to grow, manufacturers should consider leveraging automation for their plastic injection-molding operations to keep pace with rapidly changing market demands and maintain a competitive edge.

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