Packaging System Automation

Achievements and Results

-   Material handling system designed

-   Automated shipping system designed

-   Saved $125,000 per year in labor

-   Second system ordered

The Problem

A recent client in the consumer power tool industry requested help to optimize their final packaging operation. The current situation consisted of manual carton erecting, manual label application, manual scanning, manual shrink-wrapping and manual palletizing. The client was experiencing explosive growth and operated the packaging area on 2  shifts. The consultant was hired to optimize the packaging process.

The Solution

The consultant took several steps in optimizing and automating the packaging system. First, he benchmarked the current operation and identified the labor cost drivers. Second, he evaluated automation solutions within the client’s ROI specifications.

After assessing the situation, he designed specifications for a material handling system, which would transport the product from five assembly lines to a central packaging area. He then located and managed contractors to install said system.

Then, the expert designed specifications for an automated system which would apply labels, palletize tehe boxes, and shrink-wrap the pallets. This system needed to be able to handle 2,500 30-50lb boxes per shift. After designing the system, he located and managed contractors to have it installed.

Benefits Realized

The system was a success. It saved the company $125,000 per year in labor, as well as created much more ergonomic jobs for the remaining packers. The client was so satisfied, they recently ordered a second, similar system for a sister plant.

To see the resume of the expert associated with this case study, see the link below.