Factory automation is not only driven by industrial digitalization trends but also by the increasing demands of the market. To keep pace with the needs, we have established both partially and fully automated production lines capable of producing millions of plastic components annually.
In this article, we detail the methods for implementing digitalized manufacturing processes and how automation enhances quality in various areas of the manufacturing process.
How workflows change with industrial automation
Partially automated production lines still require human labor for tasks like feeding, handling, assembly, and packaging. In contrast, fully automated lines use robots to perform all necessary processes until the product is ready.
This includes:
- sorting and cyclic feeding of components,
- visual or other quality inspections of plastic parts,
- pad printing and its quality control,
- assembling and securing parts,
- comprehensive quality control of the final product, ensuring proper functionality,
- sorting and discarding defective products.
Properly developed automated manufacturing not only increases efficiency but also significantly improves quality. Robotic production lines reduce the need for human labor, minimizing errors caused by human oversight.
One major advantage of manufacturing automation is the ability to maintain consistent production quality by implementing various production standards.
Digital quality control helps determine maximum defect quantities, tolerance limits, and size ranges. Compliance with quality requirements is ensured by camera systems or other technologies like laser inspection.
Operation of an automated production line
A prime example of an efficient automated production line is the applicator for the Lenzetto Spray medical device. The process begins with loading the main components using a vibrating feeder and applicator. The component is placed on a rotating table where the elements are assembled. This is followed by ultrasonic welding and a quality check.
Before applying the paint, we treat the plastic’s closed-structure surface with plasma to generate free radicals, enhancing adhesion. The paint is then applied through a one or multi-stage pad printing process, monitored by a camera system for quality. Throughout production, data is continuously monitored to quickly identify and address any defects. The finished component is finally placed in a collection container if it meets the specified requirements.
This process is also demonstrated in our video:
Why is manufacturing automation worth it?
Industry 4.0 has shown that robotic production lines can significantly increase production capacity. Additionally, industrial automation allows manufacturing processes to run continuously, 24/7, resulting in substantial efficiency gains.
Reducing human intervention minimizes potential manufacturing errors. Precise machine calibration ensures consistently high product quality, even with increased production volumes. Quality control is implemented at multiple levels using digital cameras. For both semi-finished and finished products, we conduct
- pressure tests,
- fit checks and
- functionality tests.
The data from these tests are stored, making them traceable and providing a valuable foundation for future improvements. Finally, using enclosed-cell robots enhances the safety of manufacturing processes.
Automated production line tailored to your needs
With years of experience and a focus on our clients’ needs, we provide both in-line and off-line automation solutions. We customize each automation project to meet our customers’ unique requirements, using high-quality KUKA robots and other advanced technologies.
One of our successful projects involved manufacturing 4 million units per year of the Lenzetto Spray medical device applicator. With our advanced technology, this number can increase to 5 million. Despite the high volume, we maintained top quality through continuous data monitoring.
We are ready to automate the manufacturing of your product. Contact us, and our team will gladly provide you with more details!
