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Denso

www.denso.com

Category: Automotive
Level of automation: Highly Automated

Goals

1. to increase the efficiency of the packaging process switching from manual operations to automated systems.
2. to achieve a ROI within five years.
3. to significantly reduce the amount of oversized boxes in order to optimize stock and shipping volumes.
4. to increase the current productivity rate by 600 pcs per day.
5. to preserve the current high quality packaging.

Solution

1. Design of a highly automated system. Since the items require special handling and care an operator places them inside the box. This is the only operation still performed manually.
2. The effective ROI was achieved within two and a half years.
3. Instead of using 26 box IDs that need to be adapted one by one, the system is able to produce and manage 2307 different box sizes.
4. To ensure a high-quality packaging, the system features 2 packaging machines: one to produce and form the tray containing the items to be packed, and the second one to produce the outer packaging. The items are thus well protected inside the box and thanks to a custom-made box design a flawless high-quality box is produced.

Working Stations

1Box Procurement

Box Procurement

The system is equipped with two packaging machines.

The first machine produces the cardboard tray on which the item is positioned. It provides stability, protection and the right shape for the item, which is then packed inside the final box.

The second packaging machine produces the outer packaging in which the tray with the previously positioned items will be placed.

2Box Forming Station

Box Forming Station

An automatic tray forming station installed at the outfeed of the first packaging machine. The flaps are sealed with hotmelt glue.
At the outfeed of the station a belt conveyor moves the tray to the operator station.

3Coupling Station

Coupling Station

A coupling station is next in line.  Here the items are positioned manually inside the tray. The station is equipped with its own terminal and manual scanner to manage the changes in size of the processed batches. After the item is correctly positioned on the tray, it is automatically strapped and enters the coupling station to be fitted with the outer packaging.

At the second coupling station, an anthropomorphic robot picks up the strapped tray and places it over the outer packaging produced by the second packaging machine.

4Forming and Closing Station

Forming and Closing Station

At this station, the outer packaging is automatically wrapped and sealed. The station is divided into a first unit with two sections in which the forming and longitudinal gluing take place and a second unit with two sections where the closing and gluing of the 4 top flaps take place.

Technical features

  • Box design F410 custom
    Box design F300 custom
  • Flexibility
  • 5 pcs/min in batches
    4 pcs/min in flexibility (lot size 1)
  • MIN: L 300 X W 250 X H 110
    MAX: L 1200 X W 1000 X H 300
  • 1 Operator