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ROBOTIC
PALLET
ASSEMBLY
An overview of Robotic Pallet Assembly from
Yaskawa Motoman October 29, 2015
© Copyright by Yaskawa America, Inc.
Your customer’s demands
01
table of contents
How robotic assembly works
02
Consistent production throughput
and quality03
Employee safety
04
Impact to your business
05
Who is Jointec and
Yaskawa Motoman?06
© Copyright by Yaskawa America, Inc.
3
Your Customers are Demanding
Don’t just compete… thrive!
To compete and thrive in the pallet business you
must respond to customer demands. This
includes ever-increasing product mix and
shorter production runs.
Expensive and dedicated automation is good for
long production runs. Change over times can kill
production rates.
With robotics automation, you can thrive by
producing higher-margin, higher-quality, custom
pallets.
Use robots for the difficult jobs.
Building pallets is difficult and dangerous work.
Even minor injuries like splinters, minor cuts and
sprains have a significant impact on production
and quality.
People are good at solving problems, not
repetitive tasks.
Robots are made for mundane repetitive tasks.
Respond With Robotic Automation
© Copyright by Yaskawa America, Inc.
respond to customers
4
High Mix Production
Is change-over killing your production?
Build stringer and block pallets on the same
system.
Supports custom pallet sizes from
20” up to 120” (0.5M up to 3M).
Ideal for shorter production runs
from 25 – 1,500 units.
Automate your
© Copyright by Yaskawa America, Inc.
respond to customers
20” x 20”
48” x 120”
Block PalletsStringer Pallets
5
High Mix Production
Fast change-over, typically under
5 minutes.
Designed for custom and odd sized
pallets.
Stringer, block and custom pallets.
Automate your
© Copyright by Yaskawa America, Inc.
respond to customers
Robot with beam nailer for assembly of pre-made legs and decks
without jigs up to 1,000 pallets per shift.
6
Robotic Pallet Assembly
© Copyright by Yaskawa America, Inc.
How the Simple Nailer works
how it works
Operator loads
stingers and boards
Robot positions and
nails boards, then
stacks completed
pallets
7
Robotic Pallet Assembly
The operator loads boards
on one side
The robot works on the
other side
How the Simple Nailer works
© Copyright by Yaskawa America, Inc.
how it works
Base Robotic System
8
Robotic Pallet Assembly
The operator loads boards
on one side
Adjustable jigs are used for
stringer pallets.
Simple jigs (shown here) are
used for block pallets.
How the Simple Nailer works
© Copyright by Yaskawa America, Inc.
how it works
9
Robotic Pallet Assembly
The operator loads boards
on one side
After all boards are loaded,
the operator presses a button
and the positioner rotates
presenting boards to the
robot.
How the Simple Nailer works
© Copyright by Yaskawa America, Inc.
how it works
10
Robotic Pallet Assembly
The robot nails boards on
the other side
The robot nails boards
precisely.
As shown to the right, the
stringer boards for block
pallets are also nailed.
The system can even cleat
nails.
How the Simple Nailer works
© Copyright by Yaskawa America, Inc.
how it works
11
Robotic Pallet Assembly
The robot stacks
completed pallet
The robot can stack pallets up
to 8 feet high
How the Simple Nailer works
© Copyright by Yaskawa America, Inc.
how it works
12
Robotic Pallet Assembly
Evenly nested pallets
Typical rates for block pallets
as shown here is 70 sec per
pallet (or 50 per hour).
Rates for stinger pallets vary.
Typical rates for 40” x 48”
pallets are ~60 sec per pallet
(or 60 per hour).
How the Simple Nailer works
© Copyright by Yaskawa America, Inc.
how it works
13
Consistent Production and Quality
Robots have been used in manufacturing for over 30
years. They are fast, strong and precise!
They are very precise: the Motoman MH180 robot is repeatable to
±0.008” (or ±0.02 mm)
They are very strong: the Motoman MH180 robot can lift nearly
400 lbs (or 180 kg) – including nail guns and pallet gripper.
Motoman robots are designed to run for several years, with
minimal maintenance*
*Contact Yaskawa Motoman or see product documentation for details.
Robots are Consistent
© Copyright by Yaskawa America, Inc.
consistent production
Motoman MH180 Robot
14
Consistent Production and Quality
With labor production rates vary over time.
As workers become fatigued, production rates
drop.
Rework due to poor nailing and board placement
also slows production.
Robots are precise and consistent
throughout the day.
Robots are Consistent
© Copyright by Yaskawa America, Inc.
consistent production
Time
Productivity
labor
robot
15
Consistent Production and Quality
Quality can also suffer late in the day.
Fatigue and minor injuries impact quality.
If rework is not properly completed, you could be
shipping marginal or lower quality product.
Have confidence that the last pallet made
Friday is the same as the pallets made
Monday morning.
Robots are Consistent
© Copyright by Yaskawa America, Inc.
consistent production
Time
Quality
labor
robot
16
Building Pallets is Hard Demanding
Work
Fatigue can lead to more injuries.
As workers become fatigued late in the day,
minor injuries can occur more frequently.
Workers are often exhausted late in the day,
which can lead to more frequent injuries.
Let robots do the redundant jobs. Move
employees into higher value jobs.
Let Robots do the Difficult Jobs
© Copyright by Yaskawa America, Inc.
Time
Injuries
labor
robot
employee safety
17
Rising Costs of an Unsafe Work
Environment
Rising healthcare and workers’
compensation insurance costs are
impacting the bottom line.
Robots can lift heavier loads taking the
strain off employees and preventing
injuries.
Our robot systems are delivered with all
necessary safety guarding to ensure a safe
working environment.
Let Robots do the Difficult Jobs
© Copyright by Yaskawa America, Inc.
employee safety
Time
Injuries
labor
robot
18
Benefits Financial
Return
People
Highly flexible production that allows you to expand into custom high-
margin products.
Yes Not directly*
Safer working environment
fewer injuries and lower workers comp rates
Yes Yes
Increase efficiency and capacity with consistent and predictable
production.
Yes Not directly*
Reduces the need for jigs, which are expensive and time consuming
to maintain.
Yes Not directly*
Consistently high quality results in higher margins. Yes Not directly*
Realize growth with robotics while maintaining headcount. Yes Not directly*
Transfer people to higher value and more interesting jobs. Yes Yes
Impact to Your Business
Benefits of Robotic Automation
© Copyright by Yaskawa America, Inc.
your business
*While these items may not directly benefit how people go about their jobs, they do make the company stronger, which provides more security.
19
Impact to Your Business
With consistent productivity and higher margin products,
the payback will be sooner that you think.
Our robots are designed to run production for years, long after the
initial investments is returned. Resulting in profit for several years
in the future.
If your production needs change the robot can be
re-deployed and continue to return a profit.
Benefits of Robotic Automation
© Copyright by Yaskawa America, Inc.
your business
Time
$$
initial
investment
productivity
cost of
ownership
profit
20
Who
Yaskawa Motoman?
With over 300,000 Motoman robots
installed around the world, Yaskawa is the
global leader.
Global Footprint, Local Support
© Copyright by Yaskawa America, Inc.
who are we?
motoman.com
21
Yaskawa’s Global Footprint
© Copyright by Yaskawa America, Inc.
Global Footprint, Local Support
who are we?
Yaskawa facilities in over 25 countries with over 270,000 robots installed.
22
Regional Support Specialists
Robot Installations
Yaskawa’s Local Footprint
© Copyright by Yaskawa America, Inc.
Global Footprint, Local Support
who are we?
Yaskawa Motoman HQ
Miamisburg, OH
Yaskawa Motoman Detroit
Additional Yaskawa Motoman
facilities in the Americas
Canada
Mississauga
Montreal
Mexico
Aguascalientes
Monterrey
Brazil
Sao Paulo
Yaskawa Motoman Irvine
26 field service personnel supporting the US.
Nearly 100 people dedicated to customer service
throughout the Americas (US, Canada, Mexico & Brazil)
23
Beyond Pallet Assembly
We offer a range of products and
options for pallet assembly and repair.
Including a fully automated pallet assembly,
patented bulk nail feeders, pallet dismantling,
material handling, sorting, stamping and
marking.
Call for details.
Additional Products for Pallet Repair and Sortation
© Copyright by Yaskawa America, Inc.
who are we?
Fully automated line to build pallets with pre-made decks up to 1,600 per shift
contact information
for more information,
please contact us at
Roger Christian
937-847-3262
roger.christian@motoman.com
pallets.motoman.com
thank you

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Robotic Pallet Assembly

  • 1. ROBOTIC PALLET ASSEMBLY An overview of Robotic Pallet Assembly from Yaskawa Motoman October 29, 2015 © Copyright by Yaskawa America, Inc.
  • 2. Your customer’s demands 01 table of contents How robotic assembly works 02 Consistent production throughput and quality03 Employee safety 04 Impact to your business 05 Who is Jointec and Yaskawa Motoman?06 © Copyright by Yaskawa America, Inc.
  • 3. 3 Your Customers are Demanding Don’t just compete… thrive! To compete and thrive in the pallet business you must respond to customer demands. This includes ever-increasing product mix and shorter production runs. Expensive and dedicated automation is good for long production runs. Change over times can kill production rates. With robotics automation, you can thrive by producing higher-margin, higher-quality, custom pallets. Use robots for the difficult jobs. Building pallets is difficult and dangerous work. Even minor injuries like splinters, minor cuts and sprains have a significant impact on production and quality. People are good at solving problems, not repetitive tasks. Robots are made for mundane repetitive tasks. Respond With Robotic Automation © Copyright by Yaskawa America, Inc. respond to customers
  • 4. 4 High Mix Production Is change-over killing your production? Build stringer and block pallets on the same system. Supports custom pallet sizes from 20” up to 120” (0.5M up to 3M). Ideal for shorter production runs from 25 – 1,500 units. Automate your © Copyright by Yaskawa America, Inc. respond to customers 20” x 20” 48” x 120” Block PalletsStringer Pallets
  • 5. 5 High Mix Production Fast change-over, typically under 5 minutes. Designed for custom and odd sized pallets. Stringer, block and custom pallets. Automate your © Copyright by Yaskawa America, Inc. respond to customers Robot with beam nailer for assembly of pre-made legs and decks without jigs up to 1,000 pallets per shift.
  • 6. 6 Robotic Pallet Assembly © Copyright by Yaskawa America, Inc. How the Simple Nailer works how it works Operator loads stingers and boards Robot positions and nails boards, then stacks completed pallets
  • 7. 7 Robotic Pallet Assembly The operator loads boards on one side The robot works on the other side How the Simple Nailer works © Copyright by Yaskawa America, Inc. how it works Base Robotic System
  • 8. 8 Robotic Pallet Assembly The operator loads boards on one side Adjustable jigs are used for stringer pallets. Simple jigs (shown here) are used for block pallets. How the Simple Nailer works © Copyright by Yaskawa America, Inc. how it works
  • 9. 9 Robotic Pallet Assembly The operator loads boards on one side After all boards are loaded, the operator presses a button and the positioner rotates presenting boards to the robot. How the Simple Nailer works © Copyright by Yaskawa America, Inc. how it works
  • 10. 10 Robotic Pallet Assembly The robot nails boards on the other side The robot nails boards precisely. As shown to the right, the stringer boards for block pallets are also nailed. The system can even cleat nails. How the Simple Nailer works © Copyright by Yaskawa America, Inc. how it works
  • 11. 11 Robotic Pallet Assembly The robot stacks completed pallet The robot can stack pallets up to 8 feet high How the Simple Nailer works © Copyright by Yaskawa America, Inc. how it works
  • 12. 12 Robotic Pallet Assembly Evenly nested pallets Typical rates for block pallets as shown here is 70 sec per pallet (or 50 per hour). Rates for stinger pallets vary. Typical rates for 40” x 48” pallets are ~60 sec per pallet (or 60 per hour). How the Simple Nailer works © Copyright by Yaskawa America, Inc. how it works
  • 13. 13 Consistent Production and Quality Robots have been used in manufacturing for over 30 years. They are fast, strong and precise! They are very precise: the Motoman MH180 robot is repeatable to ±0.008” (or ±0.02 mm) They are very strong: the Motoman MH180 robot can lift nearly 400 lbs (or 180 kg) – including nail guns and pallet gripper. Motoman robots are designed to run for several years, with minimal maintenance* *Contact Yaskawa Motoman or see product documentation for details. Robots are Consistent © Copyright by Yaskawa America, Inc. consistent production Motoman MH180 Robot
  • 14. 14 Consistent Production and Quality With labor production rates vary over time. As workers become fatigued, production rates drop. Rework due to poor nailing and board placement also slows production. Robots are precise and consistent throughout the day. Robots are Consistent © Copyright by Yaskawa America, Inc. consistent production Time Productivity labor robot
  • 15. 15 Consistent Production and Quality Quality can also suffer late in the day. Fatigue and minor injuries impact quality. If rework is not properly completed, you could be shipping marginal or lower quality product. Have confidence that the last pallet made Friday is the same as the pallets made Monday morning. Robots are Consistent © Copyright by Yaskawa America, Inc. consistent production Time Quality labor robot
  • 16. 16 Building Pallets is Hard Demanding Work Fatigue can lead to more injuries. As workers become fatigued late in the day, minor injuries can occur more frequently. Workers are often exhausted late in the day, which can lead to more frequent injuries. Let robots do the redundant jobs. Move employees into higher value jobs. Let Robots do the Difficult Jobs © Copyright by Yaskawa America, Inc. Time Injuries labor robot employee safety
  • 17. 17 Rising Costs of an Unsafe Work Environment Rising healthcare and workers’ compensation insurance costs are impacting the bottom line. Robots can lift heavier loads taking the strain off employees and preventing injuries. Our robot systems are delivered with all necessary safety guarding to ensure a safe working environment. Let Robots do the Difficult Jobs © Copyright by Yaskawa America, Inc. employee safety Time Injuries labor robot
  • 18. 18 Benefits Financial Return People Highly flexible production that allows you to expand into custom high- margin products. Yes Not directly* Safer working environment fewer injuries and lower workers comp rates Yes Yes Increase efficiency and capacity with consistent and predictable production. Yes Not directly* Reduces the need for jigs, which are expensive and time consuming to maintain. Yes Not directly* Consistently high quality results in higher margins. Yes Not directly* Realize growth with robotics while maintaining headcount. Yes Not directly* Transfer people to higher value and more interesting jobs. Yes Yes Impact to Your Business Benefits of Robotic Automation © Copyright by Yaskawa America, Inc. your business *While these items may not directly benefit how people go about their jobs, they do make the company stronger, which provides more security.
  • 19. 19 Impact to Your Business With consistent productivity and higher margin products, the payback will be sooner that you think. Our robots are designed to run production for years, long after the initial investments is returned. Resulting in profit for several years in the future. If your production needs change the robot can be re-deployed and continue to return a profit. Benefits of Robotic Automation © Copyright by Yaskawa America, Inc. your business Time $$ initial investment productivity cost of ownership profit
  • 20. 20 Who Yaskawa Motoman? With over 300,000 Motoman robots installed around the world, Yaskawa is the global leader. Global Footprint, Local Support © Copyright by Yaskawa America, Inc. who are we? motoman.com
  • 21. 21 Yaskawa’s Global Footprint © Copyright by Yaskawa America, Inc. Global Footprint, Local Support who are we? Yaskawa facilities in over 25 countries with over 270,000 robots installed.
  • 22. 22 Regional Support Specialists Robot Installations Yaskawa’s Local Footprint © Copyright by Yaskawa America, Inc. Global Footprint, Local Support who are we? Yaskawa Motoman HQ Miamisburg, OH Yaskawa Motoman Detroit Additional Yaskawa Motoman facilities in the Americas Canada Mississauga Montreal Mexico Aguascalientes Monterrey Brazil Sao Paulo Yaskawa Motoman Irvine 26 field service personnel supporting the US. Nearly 100 people dedicated to customer service throughout the Americas (US, Canada, Mexico & Brazil)
  • 23. 23 Beyond Pallet Assembly We offer a range of products and options for pallet assembly and repair. Including a fully automated pallet assembly, patented bulk nail feeders, pallet dismantling, material handling, sorting, stamping and marking. Call for details. Additional Products for Pallet Repair and Sortation © Copyright by Yaskawa America, Inc. who are we? Fully automated line to build pallets with pre-made decks up to 1,600 per shift
  • 24. contact information for more information, please contact us at Roger Christian 937-847-3262 roger.christian@motoman.com pallets.motoman.com thank you