{"id":86772,"date":"2024-06-06T12:00:06","date_gmt":"2024-06-06T10:00:06","guid":{"rendered":"https:\/\/www.converter.it\/?p=86772"},"modified":"2024-06-04T16:41:53","modified_gmt":"2024-06-04T14:41:53","slug":"impack-the-business-case-for-automation-and-ergonomics-in-the-finishing-line","status":"publish","type":"post","link":"https:\/\/www.converter.it\/en\/impack-the-business-case-for-automation-and-ergonomics-in-the-finishing-line\/","title":{"rendered":"IMPACK: The Business Case for Automation and Ergonomics in the Finishing Line"},"content":{"rendered":"

By Marie-Soleil Boutet, Consulente e Area Sales Manager, IMPACK<\/em><\/p>\n

As I visit packaging producers spread across 2 continents, I see over and over again that production managers are feeling the pressure to meet production demands while observing the strain manual packing puts on their finishing line staff.<\/strong> The problem is compounded by industry-wide labor shortages. Many packaging producers experience the highest turnover rates in the packing area of the folder-gluer line. How can you meet these challenges and seize opportunities for growth?<\/strong><\/p>\n

\"Impack\"<\/p>\n

Ramping up the speed of your folder-gluer is one of the few ways to increase profits and stay competitive. The most significant folder-gluer bottleneck is the packing station. I have visited many companies that were not able to reach the maximum production potential of the folder-gluer, despite having three people hand packing. Hand packing is an extremely slow and painstaking process. The constant lifting and twisting movements cause serious repetitive strain injuries especially in the wrist and upper back. Your folder gluer is like a powerful and fast performance sports car, but with hand packing you aren\u2019t able to reach its maximum speed.<\/p>\n

In contrast, I have also observed optimized productions where automation has taken over the most strenuous tasks, transforming the workplace into a safer, more productive environment.<\/strong> By reducing personnel in these physically demanding roles, you are saving human resources for other value-added positions while increasing the speed of the folder-gluer.<\/strong><\/p>\n

You don\u2019t necessarily need to automate every packing movement.<\/strong> In fact, if you produce short runs of a variety of complex box types a fully automated solution may not give you the flexibility and net speed you need.<\/p>\n

When your packaging demands the irreplaceable precision of a human touch, the goal is to find a harmonious balance-automating the most grueling tasks while making others more ergonomic and sustainable. Other areas that benefit from various levels of automation are pre-feed, case management, case sealing and case palletizing functions.<\/p>\n

Semi-automated Packing Solutions<\/strong><\/p>\n

Semi-automated packing stations reduce bending by incorporating shelves for samples and breakers at the packing station. Box turners are one of the best ways to reduce movements that can cause repetitive strain wrist injuries. Accumulation conveyors will control the density and flow of the shingle allowing a single worker to multi-task.<\/p>\n

Automation can eliminate bottlenecks that limit folder-gluer speed.<\/em><\/strong><\/p>\n

\"Impack\"
Calculating invisible costs<\/strong><\/figcaption><\/figure>\n

Perhaps your mental calculator is already at work asking, \u201cAt what cost?\u201d<\/p>\n

The more critical question emerges: What is the cost of not investing in some automation? Consider the costs incurred from sick days and leaves of absence due to repetitive strain injuries in your facility over the past 5 years. Reflect on where your facility experienced the highest turnover. Calculate the actual cost of hiring and training new employees.<\/p>\n

The real business case for ergonomics and automation in the packing area is in employee retention and increased capacity.<\/strong><\/em><\/p>\n

Calculating ROI for Automation Investments<\/strong><\/p>\n

Identify which manual tasks consume the most time and lead to repetitive strain injuries. By determining the time spent manually pre-feeding, packing, sealing, and palletizing you can ascertain the output and labor costs associated with these tasks. Return on investment can be quickly ascertained based on the increase in productivity, the life of the machine, and the cost of wages for the re-deployed workers.<\/p>\n

After realizing initial ROI, packaging producers continue to experience profit gains due to increased capacity and the ability to fulfill increased demand.<\/p>\n

We have developed ROI calculators to help packaging producers meet their profit objectives and have clients that have realized the following return on investment:<\/p>\n