Molders look to automation for survival

As plastics processors seek to stabilize shrinking bottom lines, automation system suppliers report heightened interest in robots.

The latest models exhibited at NPE 2003 were marketed as faster, more flexible, and easier to use. More important to processors is using the technology to achieve quality control, cost and profitability goals.

"The business climate for robotics and automation equipment for the plastics industry is likely the best it has ever been as North American processors look at what they need to do for survival," declares Todd Rains, national sales manager, Wittmann Inc. "Capital expenditures are much less now than they were five years ago and companies want to spend more wisely. Although most are not spending on new machinery, they are investing heavily in automation."

Indeed, sales of robotic automation and other auxiliaries in North America climbed in 2002, suppliers report, a significant accomplishment in light of an economic climate that caused many molders to scale back on capital expenditures.

Because the North American market traditionally has had a higher labor/machine ratio than most of Europe and many Asian countries, it is considered to still have plenty of room for automation growth.

"Even when robots take care of part picking and machines run automatically, there are usually labor-intensive downstream functions like assembly, finishing, inspection, and packing that can still be automated," says Hank Dixon, executive VP, automation, at Conair. "I think that's at least part of the reason automation sales have improved over the last year and a half."

Automation system suppliers exhibiting at NPE cited other reasons for increased sales, but none more important than the opportunity for molders to update manufacturing operations, and thereby improve productivity and profitability.

"Although many companies may not be in a position to buy new molding machines, they want to invest in upgrading their current work cells and plants to immediately impact their bottom lines," says Wittmann President David Preusse. "With advanced automation, they are able to improve their part quality and reduce scrap while minimizing labor costs."

Most molders agree automation is key to realizing production gains. For instance, automation solutions are viewed as essential to helping high-speed injection molding machines keep pace with their smaller counterparts.

"Those solutions that can help keep cycles down on large systems [offer] a growth advantage," says Paul Thomson, a spokesman for Husky Injection Molding Systems Ltd. "In general, labor costs and reliability are key factors influencing the importance of automation going forward."

Husky showed off its Hylectric 1000 1100-ton injection molding machine, which features SwingChutes, a key in-mold automation solution. SwingChutes and downstream product handling eliminate traditional handling problems, including high labor and equipment costs and part damage. The system shown at NPE produced 7.25-inch-diameter food containers in a 5.9-second cycle. "SwingChutes also improve cycle time, reliability, and machine utilization while reducing floor space and scrap," says Jim Overbeeke, Husky's sales manager for thin-wall packaging. "SwingChutes are contained between the machine's tiebars, reducing floorspace by up to 40 percent."

Jobless growth?

Robotic automation is marketed as an economic alternative to buying new molding machines to increase production. Robots sell for roughly 20 percent less than they did five years ago, and are more efficient and versatile, providing molders with greater value.

"Robotic automation can be utilized to get more parts from existing machines as robots can beat the cycle time of gravity-dropped parts and increase the productivity of manually loaded machines," points out Richard Johnson, general manager, material handling, Fanuc Robotics America Inc.

"At the same time they provide more flexibility to accommodate production changes, can handle post-processing jobs, are very fast and accurate, and provide a quick return on investment."

Engel North America's fifth robot generation, the ERC-E Series, features improvements to mechanical features, transmission and input/output technology, and control technology (photo, top p. 34).

"The resultant modular system featured by the new E Series offers the processor, in comparison with the previous series, more performance for less money," says Harold Luttmann, manager, robotics and automation. "This includes higher speeds and faster rates of acceleration as standard features, different selectable levels of performance by means of digital drive systems, extended maintenance intervals and easier servicing, digital vacuum monitoring of suction grippers, a wider choice of modules as additional options, and a considerably improved cost-performance ratio."

More and more processors are becoming convinced the time is right to incorporate automation in their facilities' operations, suppliers say. "The bottom line is that robotic automation is much more affordable then previously thought," Fanuc's Johnson says.

At NPE, Fanuc introduced RoboGuide/SimPRO, off-line robot simulation software that allows companies to develop and test a robot application via simulation. SimPRO simulates general-purpose material handling applications including pick-and-place, machine load/unload, packaging, material removal, assembly, and palletizing.

NPE displays also reflected the trend towards systems integration. Robots can offer significant added value when used in a work cell to remove parts from the machine and handle downstream operations such as material removal, assembly, packaging, and labeling.

"The advanced control platform of Wittmann robots, combined with the simple operator interface, provides the ability to integrate and control all the downstream equipment using the robot as the master slave," Rains says. Other auxiliaries can be added to the work cell and connected with the robot. One example of this is the combination of a sprue picker and granulator.

JIT customization

Another reason for heightened interest in robots may be the fact that today's units are more flexible and easier to use in just-in-time manufacturing situations. Conair cites its new Generation IV beam robots as an example. "The new 'Visual' control, which is now the standard controller on all Conair Sepro robots, has more functionality and more memory than other systems currently on the market, yet it is much easier to use" claims Jim Healy, automation sales manager.

John M. Mallon IV, president of Yushin America Inc., says a robot's flexibility is based on such criteria as number and type of axis motions, size of the work envelope, axis drive method, payload, speed, programmability, ability to control and interlock to secondary machines or processes, and ease of operation.

"The higher the level of specification in each category, the greater the robot's flexibility, and the greater its potential to generate cost savings through value-added work," he says. "Savings may not be maximized on the first project, but can be considerable on future ones because of low retooling costs."

Processors also require articulated robots as an alternative to gravity feed or traditional extractors. "Speed is always a consideration due to the desire to reduce the amount of time required for mold open time as is increased articulation for the extractor robots, so that inserts and labels can be added prior to the part being formed," Fanuc's Johnson says. Consequently, Fanuc offers pedestal robots and articulated gantry products.

The newest robots at NPE were said to be easier to set up and do not require extensive operator training.

"[They are] flexible enough to be adapted to changing production situations, including the need to function in combination with other equipment in a wide range of applications, in and out of the molding machine," Conair's Dixon says. "[They have] powerful controls that can perform the most complex tasks and communicate with the other equipment involved in the process."

Wittmann's Rains notes the integration of robots with the molding machine through a standard SPI interface, coupled with advances in controls, results in easier operation and programming of more advanced sequences.

Overall, the latest automation solutions shown at NPE are designed to help processors deliver value-added products to customers.

Says Rains: "Where robots once had the image of eliminating jobs through labor reduction, they are now seen as an opportunity to not only save manufacturing jobs, but to create opportunities for skilled individuals to operate and maintain them."

Greg Valero [email protected]