Robotics Myth 2: Shortest Path ≠ Fastest Path

Consumer Buying Habits: How Does This Affect Automation Needs? With rising technological advancements, automation is becoming a vital part of all businesses. One key factor driving this necessity is the shift in consumer buying habits. According to recent studies, there has been a significant rise in wholesale and eCommerce purchases. For example, eCommerce sales in the United States alone reached $815.4 billion in 2020, marking a 43% increase from the previous year. It is also expected that by 2026, 24% of retail buyers will make their purchases online. This surge in online shopping comes with a demand for different packaging methods compared to traditional retail purchases. As businesses adapt to meet these changing consumer needs, there's a growing realization that automation and robotics must also evolve. Changing Consumer Buying Habits The US eCommerce market grew by 7.6% in 2023 strongly indicating changing consumer buying habits. This shift is having a big impact on how businesses operate, especially in terms of automation. Let's take a closer look at why people are increasingly shopping online and what it means for companies: Convenience and Accessibility: Online shopping platforms offer great convenience and accessibility to buyers. This is one of the biggest factors why 62% of Americans today prefer buying their necessities online. Cost-Effective: Availability of various vouchers, cashbacks, discounts, etc., make online shopping a more cost-effective option for consumers. This has increased the possibility of millennials choosing online shopping by over 23%. Expansive Product Range: Modern buyers today are not only keen on getting products at the best rates possible, but they also want the best products. Wholesale or eCommerce shopping platforms fulfill this need successfully by allowing consumers to access a diverse range of products suiting various preferences. Impact on Packaging Automation While consumer buying habits are rapidly shifting towards wholesale or eCommerce buying, here is how companies are struggling: Fluctuating Order Volume & Frequency: Unlike traditional retail settings, wholesale and eCommerce orders show significant variability in order volume and frequency. Automation systems must possess the flexibility to adapt to these fluctuations and maintain operational efficiency. Diverse Packaging Requirements: Wholesale and eCommerce orders demand tailored packaging solutions. Companies are expected to accommodate bulk shipments or customized packaging preferences. Therefore, automation systems must be equipped to handle diverse packaging requirements, ensuring swift and accurate order fulfillment. Logistical Challenges: The increase in online orders presents logistical challenges for businesses, particularly concerning packaging and shipping. Automation plays a crucial role in streamlining logistical operations, from order processing to packaging and shipping, to ensure timely and accurate delivery of products to customers. Different Packaging Needs for Wholesale/E-commerce vs. Retail Wholesale, eCommerce, and retail – all three have varying packaging needs. Understanding these will enable businesses to customize their packaging solutions to meet customer expectations and increase retention. Let’s take a look at the unique packaging needs for wholesale, eCommerce, and retail: Bulk vs Individual Packaging: Wholesale orders often entail bulk packaging whereas, eCommerce orders typically require individual packaging to accommodate the diverse preferences of online shoppers. On the other hand, retail packaging varies, but it commonly involves individualized packaging to attract customers and facilitate shelf display. Customization Options: A study recorded that 52% of consumers are likely to return to a brand if their products are packed exceptionally. And ecommerce packaging offers a memorable unboxing experience for customers by providing opportunities for customization. Retail packaging may also incorporate branding elements and product information to attract shoppers and communicate value. However, they lack customized packing options. Packaging Materials and Durability: A survey recorded that as high as 67% of buyers are influenced by packaging materials used. This stresses the importance of using durable materials for packing consumer goods. Wholesale packaging focuses on durability and cost-effectiveness, often utilizing sturdy materials for bulk shipments. eCommerce packaging requires a balance between protection, sustainability, and adequate cushioning to safeguard products during transit. Retail packaging prioritizes aesthetics and shelf appeal, with attention to design elements, colors, and finishes that resonate with target consumers. Packaging Efficiency and Automation: Wholesale packaging may involve automated processes for palletizing and shrink-wrapping bulk shipments. eCommerce packaging automation focuses on order fulfillment and packaging customization. Retail packaging automation may encompass labeling, barcoding, and product presentation enhancements to optimize shelf visibility and inventory management. Adaptability of Automation and Robotics In response to the changing consumer buying habits, automation and robotics play a crucial role in meeting the evolving needs of businesses. By investing in flexible automation solutions, businesses can optimize their packaging processes, enhance operational efficiency, and meet the dynamic demands of modern buyers effectively. Here's a closer look at the adaptability required in automation systems to accommodate the diverse packaging requirements: Customizable End-Effectors and Programming: Robotics solutions must offer customizable end-effectors to handle varied packaging requirements. They must also come with flexible programming capabilities that would allow business owners to adjust packaging processes based on specific product characteristics and packaging preferences. Efficient Handling of Diverse Packaging Requirements: Robotic solutions must demonstrate versatility in handling diverse packaging materials, sizes, and shapes. Adaptive grippers and conveyance systems optimize handling processes, ensuring seamless packaging operations across different product categories. Scalable Software Solutions: Scalable software solutions enable businesses to customize their automation processes to their specific needs and scale operations as their business grows. Additionally, these solutions must come with user-friendly interfaces and intuitive tools that would allow operators to modify automation parameters easily. Seamless Integration with Existing Infrastructure: Robotic automation systems must seamlessly integrate into the existing production line to ensure minimal downtime and implementation costs. These solutions will not only allow business owners to optimize their operations but also maintain continuity in their workflow. With the increasing prevalence of wholesale and eCommerce purchasing, addressing unique packaging needs and integrating flexible automation solutions becomes crucial for businesses. Embracing these automation systems allows companies to meet evolving consumer demands effectively and maintain competitiveness in today's market. You can learn more at info@southie.com .

How to Champion Automation for Your Company? Integrating automation into your company is a decisive step towards improving productivity and staying ahead in the competitive market. Robotic arm solutions, for instance, offer a unique opportunity for companies to improve their operations. However, embracing automation extends beyond the mere acquisition of technology. It requires a thoughtful approach that involves getting your team on board, aligning your business goals with automation strategies, and overcoming common investment concerns. This blog will take you through the essential steps of adopting robotic arm solutions to ensure your business reaps the full benefits of automation. With a clear approach, we'll help you navigate the challenges and opportunities that come with integrating automation into your operations. Looking to Start Acquiring Robots in Your Company? Robots in your company can significantly boost efficiency and streamline operations. But before you proceed, there are crucial factors to consider ensuring a successful integration. 1. Get Team Buy-in By taking a structured approach to team buy-in, your company can smoothly navigate the complexities of integrating automation technologies. This not only ensures a higher likelihood of successful implementation but also sets the stage for a future where your business remains competitive and agile. Select Your Automation Team: The first step is to assemble a dedicated group of individuals who will spearhead the implementation and ongoing management of your automation solutions. This team will serve as the cornerstone of your automation efforts. They will bring together expertise from various fields to address technical challenges and optimize operational efficiency. Engage the Operations Team: The success of automation completely depends on the acceptance and cooperation of those who will interact with these technologies daily. Therefore, it's crucial to engage your operations team early in the process, inviting their input and addressing any concerns they may have. This will help you foster a sense of ownership among your team members, and you will also be able to ensure that the solutions you are implementing are practical and meet the real needs of your business. Secure Leadership Support: Perhaps the most critical aspect of championing automation within your company is gaining the backing of your leadership team. Their endorsement is not just about securing the necessary financial investment; it's about creating a vision for the future where automation plays a key role. Presenting a compelling case that outlines the benefits of automation, backed by data and clear outcomes, will help persuade decision-makers to support this transformative journey. 2. Strategic Review of Automation Approaching automation with a strategic mindset will ensure that the introduction of robotic arms and other automation technologies lead to sustained improvement and growth in your company. This structured approach lays a solid foundation for your automation journey, enabling your business to maximize the benefits of these innovative solutions. Let’s break down the essential steps in this process: Understanding the Business Problem: The starting point is to pinpoint the specific challenges your company faces that automation could solve. This involves a deep dive into your current processes to identify bottlenecks, inefficiencies, or quality issues. With a clear understanding of these problems, you can tailor your automation solutions to address them directly, ensuring that your investment delivers tangible benefits. Aligning Stakeholders: Achieving a consensus among all key stakeholders is critical before moving forward. This means ensuring that everyone, from team leaders to department heads, understands the automation goals and how these align with the broader business objectives. Open discussions and collaborative planning sessions can help harmonize perspectives and set unified expectations, paving the way for smoother implementation. Developing a Plan of Action: With a clear understanding of the problems and stakeholder alignment, the next step is to draft a comprehensive action plan. This plan should outline the specific automation technologies to be adopted, the implementation timeline, the required investment, and the expected outcomes. It's also vital to include metrics for measuring the success of the automation initiative, such as productivity gains, cost savings, or improvements in quality. Overcoming Investment Concerns Addressing financial concerns is a crucial step when considering the integration of robotic arms into your company's operations. It's natural for there to be apprehension about the initial outlay required for such technology. Here are strategies to help overcome these investment concerns: Detailed Cost-Benefit Analysis: Begin with a thorough evaluation of the costs involved versus the expected benefits. This analysis should cover the immediate financial outlay and long-term savings in labor, increased production speed, reduced errors, and the potential for higher quality products. Quantifying these benefits can provide a clearer picture of the investment's value. Assessing Risk of New vs. Traditional Technology: With any new technology, it’s important for stakeholders to assess the risk differently than they would with traditional fixed automation. The benefit for advanced technology that increases flexibility will far outweigh the immediate risks of incorporating new technology into existing processes. ROI Forecasting: Calculate the return on investment by estimating how long it will take for the savings and efficiency gains to cover the initial costs. This forecast should be realistic, considering the time needed for implementation and your team's learning curve. Financing Options and Incentives: Explore different financing options that can ease the burden of initial investment. This might include leasing equipment or taking advantage of payment plans offered by suppliers. Additionally, look into government grants, tax incentives, or subsidies available for companies investing in technology upgrades. Now is the time for companies to set aside any hesitations and embrace the advantages of automation. By doing so, they position themselves for better efficiency, innovation, and a competitive edge in their industry. The journey towards automation requires careful planning and execution, but the benefits far outweigh the initial obstacles, marking a significant step forward in a company’s growth and evolution. You can learn more at info@southie.com .

SOPs in Production Line Optimization: Manual vs Robotic Operations In the manufacturing and packaging industry, Standard Operating Procedures (SOPs) are essential for ensuring smooth production lines. The guidelines mentioned in these SOPs ensure every step, whether performed manually or by robots, contributes to optimal performance. As per a case study, successful implementation of SOPs can result in up to 33% reduction in lost-time incidents and up to 50% reduction in quality-related issues. This blog explores the role of SOPs in production line optimization. We will discuss the challenges faced in manual operations like workload balancing and human variability, and how SOPs help mitigate them. Additionally, we'll discuss the advantages of robots in maintaining consistent performance and how SOPs guide robotic integration. Understanding SOPs in both settings is crucial for streamlining operations and boosting overall productivity. Manual Operations: Implementing SOPs for Efficiency Absence of a well-defined SOP can lead to reduced productivity, miscommunication, quality issues, increased risk of accidents, and so much more! Therefore, when it comes to ensuring factory-wide unified way of performing day-to-day manufacturing operations, implementing a SOP is non-negotiable. They provide a structured approach to managing various challenges that manufacturers might encounter in manual production lines. 1. Challenges with Line Balancing Line balancing refers to the process of distributing tasks evenly among different workstations along a production line. This ensures that each station has approximately the same amount of work to do, thereby maximizing overall productivity by up to 34%! However, different tasks have varying durations and resource requirements, making it difficult to maintain the required balance along the production line. These challenges often lead to frequent stops, disrupted workflows, and reduced overall efficiency. Here’s how implementing a SOP solves this issue: SOPs provide detailed guidelines that offer a systematic approach for addressing these issues allowing manufacturers to optimize task allocation and resource utilization. By adhering to SOPs, manufacturers can quickly identify and rectify imbalances, ensuring smooth and continuous operation of the production line. 2. Managing Human Variability Human variability, including differences in skill levels, work speeds, and approaches to tasks, presents another challenge in manual operations. These factors lead to lack of coordination, delay in meeting schedules, unexpected errors, etc. Take a look at how a SOP helps manufacturers tackle these issues: SOPs standardize processes and provide clear instructions for consistent task performance. Training programs based on SOPs ensure that all workers understand their roles and responsibilities, contributing to a more cohesive and efficient workforce. Additionally, SOPs include strategies for monitoring and adjusting workflow to accommodate variations in individual performance, further enhancing overall efficiency on the production line. Robotic Operations: SOPs for Consistency and Performance In modern manufacturing, robotic operations have become increasingly prevalent due to their efficiency and precision. In fact, a recent World Robotics Report recorded that there is 1 robot for every 71 employees in the manufacturing industry. But how do manufacturers ensure that these robots operate at their best? Through SOPs! They serve as a set of guidelines that define how robotic operations should be conducted in a factory. This helps ensure consistency and optimal performance throughout the production process. 1. Maintaining Continuous Operations Robots work best when they operate continuously with very few stops as frequent stops interrupt the workflow and reduce overall productivity. Therefore, manufacturers must ensure continuous robotic operations for maximizing productivity, meet demand schedules, and increase customer satisfaction. SOPs outline procedures for maintaining continuous operation in robotic production lines and help manufacturers ensure consistent robotic operation. SOP guidelines ensure consistent execution of tasks, minimizing variability and optimizing efficiency. SOPs outline maintenance schedules for robots, reducing the likelihood of unexpected breakdowns and minimizing downtime. SOPs facilitate training for operators, ensuring they are knowledgeable about proper robotic operation and maintenance practices. 2. Ensuring Peak Performance The best part about having robots in your production line is they can run at maximum speed for multiple shifts without compromising quality. For example, some robots can work for up to 70,000 hours, sometimes more at a stretch...your employees can’t. To maintain these peak performance levels in robotic operations, SOPs are essential. Guidelines specify procedures for optimizing robot performance over extended periods, ensuring consistent output. Adherence to SOPs ensures reliable robot performance across shifts, contributing to overall operational efficiency. Additionally, SOPs include protocols for routine maintenance and performance monitoring, further enhancing operational effectiveness. In conclusion, Standard Operating Procedures (SOPs) play a critical role in enhancing efficiency and productivity in both manual and robotic operations. By providing clear guidelines and protocols, SOPs address the unique challenges faced in each production method, from balancing tasks in manual operations to optimizing performance in robotic settings. To maximize their effectiveness, manufacturers should prioritize the development and optimization of SOPs, ensuring they are tailored to the specific needs of their operations. By adhering to best practices and continuously refining SOPs, manufacturers can streamline processes, minimize downtime, and ultimately achieve higher levels of efficiency and profitability in their manufacturing environments. Sources: https://praxie.com/robotics-in-manufacturing/ https://roo.ai/SOP-for-manufacturing-the-blueprint-for-consistency-and-quality-control/ https://4industry.com/blog/everything-about-SOP/ https://www.compliancequest.com/blog/manufacturing-operations-with-SOP-management/ You can learn more at info@southie.com .

Say No to High-Precision Automation: Embrace Flexibility in Manufacturing The modern manufacturing and packaging industry has long been dominated by high-precision automation due to the need for utmost accuracy and consistency. These processes allowed manufacturers to meet evolving customer demands, improve efficiency, and drive overall growth. However, with the evolving industry, the traditional approach of high-precision automation is now facing its own set of challenges. The rigidity and exorbitant costs associated with precision automation in manufacturing no longer align with the dynamic needs of the market. As a result, manufacturers find themselves grappling with the limitations imposed by these systems, struggling to adapt to shifting consumer preferences and evolving packaging trends. This blog explores the transition from high-precision automation to flexible automation which is a more resilient, agile, and cost-effective approach. The Limitations of High Precision Automation for the Manufacturing Industry While high-precision automation offers several advantages, the following limitations pose significant challenges to manufacturers who seek flexibility and adaptability in their business operations: High Integration Costs: Implementing high-precision automation systems often incurs substantial upfront expenses due to the need for sophisticated hardware and software components. Inflexibility in Production Processes: High-precision automation systems are designed for specific tasks and lack the versatility to easily accommodate changes in product specifications or packaging requirements. Limited Scalability: Expanding or modifying high-precision automation setups to meet increased production volumes or accommodate new product lines can be both complex and costly. Incompatibility with Market Trends: The rigid structure of high-precision automation makes it challenging for manufacturers to quickly respond to evolving consumer preferences and shifting market demands. Maintenance and Downtime: Complex high-precision automation systems require specialized maintenance, which may lead to extended downtime periods and increased operational expenses. Obsolete Systems: Rapid technological advancements may render high-precision automation systems obsolete, necessitating frequent upgrades or replacements to maintain competitiveness and relevance in the market. Flexibility in Automation: Why It Is the Need of the Hour? Adapting technological solutions that offer flexibility represents a paradigm shift away from the constraints of high-precision automation. Flexibility in automation offers a more agile and responsive manufacturing approach which can help brands overcome the limitations of traditional automation systems. Flexible automation solutions offer a range of benefits that directly address the challenges posed by high-precision automation: Adapting to Marketing Trends: With flexible automation, manufacturers can swiftly adjust production processes to align with emerging market trends. Whether it's introducing new product variants or modifying existing offerings, flexible systems enable agile responses to evolving consumer demands. Personalized Packaging: Personalization is now key to capturing consumer attention and flexible automation allows for the customization of packaging designs and product configurations. By leveraging adaptable technologies, brands can cater to individual preferences without sacrificing efficiency or scalability. Seasonal Packaging: Flexible automation facilitates the seamless transition between different packaging requirements. Therefore, manufacturers can easily accommodate seasonal variations in product packaging. Efficiency and Cost-Effectiveness: High-precision automation requires significant reconfiguration or investment to accommodate changes. On the other hand, flexible automation solutions offer inherent scalability and versatility. This allows manufacturers to optimize production processes without incurring excessive expenses. Enhanced Agility: Flexible automation empowers brands to respond swiftly to market fluctuations and competitive pressures. By embracing adaptable technologies, manufacturers can capitalize on opportunities and mitigate risks more effectively, maintaining a competitive edge in a rapidly evolving landscape. Trending Flexible Automation Solutions In response to the limitations of high-precision automation, manufacturers are increasingly turning to a variety of flexible automation solutions. These technologies offer the versatility and adaptability needed to address the challenges posed by rigid automation systems: Robot Arm Solutions: Robot arms are versatile automation tools that can perform a wide range of tasks with precision and efficiency. Unlike fixed automation systems, robot arms can be easily reprogrammed and reconfigured. Their flexibility allows manufacturers to integrate them into existing manufacturing processes while maintaining the agility to handle diverse product variations and packaging needs. Collaborative Robots (Cobots): Cobots are designed to work alongside human operators. By combining the strengths of human workers with the precision and repeatability of robots, cobots enable manufacturers to achieve greater flexibility and efficiency in their operations. These collaborative robots can easily be redeployed to different tasks or production lines, making them ideal for dynamic manufacturing environments where adaptability is crucial. Automated Guided Vehicles (AGVs): AGVs are autonomous vehicles equipped with guidance systems, such as lasers or magnetic strips, that enable them to navigate manufacturing facilities and transport materials or products between different locations. These versatile robots can be programmed to follow predefined routes or respond to dynamic changes in their environment, making them ideal for material handling and logistics tasks. By automating transportation processes, AGVs enhance efficiency and flexibility in manufacturing operations, allowing for seamless integration with other automation technologies. The future of manufacturing lies in flexible automation. With advancements in technologies like robot arms, cobots, and AGVs, the industry is poised for growth. By integrating these solutions, manufacturers can eliminate the need for high-precision automation and adapt a more cost-effective and agile approach to production. Flexible automation has the potential to unlock new levels of productivity and competitiveness, shaping the future of manufacturing for years to come. You can learn more at info@southie.com .

What Does Your Copack Operation Have In Common With A Disney Movie? I’ve learned that it pays to be friends with the maintenance department.. My phone’s contact list has as many maintenance people in it as operations managers. That’s from lessons learned - in contract packaging and manufacturing. Why? They know stuff. They will find answers. They get things fixed. They also know equipment. What works well as well as what are the dogs. And that was the reason I was reconnecting with Isaac. I wanted to talk about robots in co-pack. (Not his real name. He’d say “You CAN use my real name. The bosses know I’m a straight shooter.” And he is. But I can’t help feeling that I need to make sure when we finish talking, he’s still in the best standing and gave me an unfiltered “voice from the production lines”. With labor shortages and the price of robot arms aligning favorably, plus some suppliers making the cost of an arm the same per month as a worker takes home in paychecks (through a Robot-as-a-Service RaaS model), I figured that Isaac would have some experience. Me getting unfiltered and straight shooter style instead of just points from a website’s sales pitch. All operations in contract packaging (or manufacturing) have “boneyards”. You may have seen pictures during the pandemic when airlines lost more than half their business, they stored 737s in a boneyard in a desert (that here in 2023 you are probably now flying in again). Why? It’s surplus to be reused or recycled or scrapped. In every co-pack operation I’ve visited there are boneyards, holding areas, surplus equipment areas or other named parking places. Some small, some big. Given the high mix and constant changeover needed in secondary packaging these are essential. A cartoner might not be needed on Line #6 today, but the weekly schedule says it needs to be set up by the second shift Friday. The place can also be the equivalent of a junk drawer. Think of it as “MacGyver is alive and well - he’s just wearing a maintenance shirt”. Some pieces are there to be taken apart and their components go on to help with some process improvements. A bigger motor on that conveyor will pull the weight of a belt struggling under twenty cases of detergent. Kind of an “organ donor” scenario. And Isaac and his creative team have done their share of transplants. It's also where bad ideas go to die. Picture it as the opposite end of the spectrum as a PackExpo – where the latest greatest newest ideas in equipment are there for people to see and envision on their production floors. All are good --- the trick is figuring out are they good for YOU? A new Tesla model 3 is pretty good technology…but if you are the one taking three kids and their three friends to soccer practice twice a week, you’re going to need a third row vehicle to be “good for you”.) A new piece of equipment that doesn’t cut it on the co-pack floor will find itself parked back in the boneyard. There you can find “do not touch” investments made by well-intended engineers or under informed decision makers. Accounting says to depreciate it for five years but you discover in year one it was a bad choice…with a price tag in the many thousands and at annual asset list review time you’ll need to answer: “What’s it going to take to get rid of?” (Well, you’d have to find a buyer. A buyer in the used equipment market, and one that is in your type of business, that happens to be looking and happens to have an approved budget and will probably offer half or less of your remaining book value. Then you have to convince the accountants that it’s OK to take a loss. (spoiler alert – it won’t be OK). Then somebody starts talking about who made this decision. It's not the latest mystery on Netflix but can turn into the co-pack version of “Knives Out”. Which is what I was asking Isaac about. The innovators leading successful contract packaging companies have already started using robot arms on their lines or are one budget away from doing so. They get it. The labor shortage isn’t going away. Workers have better choices now and they are making them. Repetitive jobs like placing products destined for a large retailer’s shelves onto conveyors to be shrink wrapped into “buy one get one free” packs for forty plus hours a week are going unfilled as wage battles get fought at distribution centers clustered around every other interstate cloverleaf in the US. There will be no influx of new or future citizens (and line workers) to surge and cover any unemployment deficits. Isaac knows that. He’s short by two maintenance techs to cover two shifts (three at peak season every Fall). That means constant juggling to keep what lines that are staffed running. Running and making money. Copack executives are finding it an interesting “IF-THEN” exercise. IF I don’t automate to close these gaps THEN I need to accept that my lines will be understaffed. IF they are understaffed THEN I need to slow them down. IF I slow them down THEN I miss deliveries or miss my profit targets for that SKU. IF I miss deliveries THEN customers will play the “next co-packer up” game and my revenue drops. IF I lose customers or profit THEN… Well, that’s usually when reality or good logic show that investing in technology like robot arms is the best approach today. Back to the front lines – and Isaac. He wants to know what’s on my mind (and I know that he is multi-tasking as we speak. Paying attention but also eyeing the floor and spotting an unexpected red Andon light telling him he might be getting paged if it doesn’t flip to green in the next couple of minutes). “Robots.” I say. And so I ask him, “Has your boneyard added any robots in the last year or two?”. I heard the chuckle before he said. “Luckily, no. But we came this close”. “Really? What happened?”. And then it was my turn to smile as I listened to a story I’ve heard too many times in the last few years from co-pack operations. Short version goes like this: Getting a robot WAS the right decision. But the choice of who to work with was not. All robot arms look great on the website video or in the convention center hall. The aisleway math done at the show booth made sense. Their co-pack operation could make X$’s more if missing positions were filled, they could run extra shifts, save OT etc. Enough to hit the payback period and ROI to keep financial folks happy. But what many find out (too late – after installing and running under longer real world conditions) is that the CHANGEOVER costs can kill all the positives about the new technology over on Line #3. Face it. Most co-packers are lucky to have a minority of lines running all but the same product night and day. Little or no changeovers (or once a month). The other lines? That’s life in co-pack: production runs that last under a full shift. A stream of SKUs next up. All short run high mix. As Isaac explained “Not the kind of work that can just sit and wait.” “Wait for what?” I asked. “Me. Or my team. If the robot needs a techie like me or even an engineer then it’s going to wait till we’re available. And then wait some more. Many don’t tell you it may stretch to hours for that to happen and then the time for us to program in all the parameters, test it out, rinse repeat.” “So, you passed on the robot arm?”. “Yep. For now.” My turn to smile again. “Isaac, that is more common out there than you would think. But there is one company I’ve run across that has delivered on making changeover in a matter of minutes not hours. And often with floor leads using the tablet, not you or your team of techies”. We spent a few minutes talking about Southie Autonomy. Their system is tailored for contract packaging floors and runs on any brand of robot arm – your choice or have them recommend. And the integrated camera that sees product coming to it – no need to add in more hidden costs for complicated fixtures and chutes to get it exactly in one spot and only one spot for the robot to grab. Isaac said thanks. I knew he was thinking about that red Andon light. I also knew he’d be looking up Southie on his lunch break, no doubt. The good thing is his company really does respect him and his people. And if it says it’s a good thing to consider, then it is. “Oh, one more thing.”, Isaac said. “Back to your first question. Yes, we did add to the boneyard. We added a Bruno”. I thought hard. “Bruno? Bruno?…”. I know most equipment companies out there in co-pack. But new ones emerge every day. I drew a blank and asked him to tell me about “Bruno” and why their technology ended up parked in his boneyard. “It’s not actually a company. Bruno is just what we call it.” And paused. For effect. “We don’t talk about Bruno, no, no, no!” (That song. It immediately came back to me. If you don’t have a young person in your life who has sung it a hundred times from the back seat on a road trip, look it up. It’s from the Disney movie “Encanto”. Catchy but kids have been known to sing that line over and over until the adult in the room or SUV distracts, bribes, does whatever it takes to stop it.) Before I could ask he continued. “Yeah we don’t talk about Bruno. On once a year executive visits there’s a tarp over it. Like a few others, it's best to just not talk about the money spent on a piece that just didn’t work out. Makes things uncomfortable. Hey. I gotta go”. And that’s what you are left with as you look at your co-pack operation. You will be considering robots. I’ll take that bet. Copack is made for using these to supplement their workforce. The forward thinkers are testing or installing now and many more to follow. Just be sure to include a call to Southie if you do look into robot arms for your packaging or even manufacturing lines. You don’t want to buy any Bruno’s. John has spent over thirty years learning in global manufacturing, automation, engineering, 3PLs and contract packaging. Currently still learning and sharing best practices in those fields and as an advisor to Southie Autonomy out of Boston MA. You can learn more at info@southie.com .

The Two Biggest Mistakes People Have Shared About Buying A Robot For Contract Packaging Only two? No, sorry to say, there’s more and those will be shared in another post. But for now, here in 2023 are the top two things that I have heard when talking to people in the industry: that if you figure out BEFORE you issue a PO for that new robot (or robots) on your contract packaging line you will be ahead of the game. Here’s the setting. The two of us are out on the co-pack floor standing at one of just under twenty lines. The products are typical of what you’d see at most standalone co-packers that serve many customers, or one that’s embedded in some large Fortune 100 CPG. Things you’ll be picking up on your next trip to Target or CVS or any other chain. Fresh from the factory, being re-packaged in the form that the consumer will notice, grab off the peg hook and toss in the cart. We are looking at his latest purchase – a robot arm. He is the site manager. Has been in co-pack awhile. We are on the production floor with about ten of those lines in full swing mid first shift. Conveyors, shrink wrappers, cartoners, clamshell sealers humming away in a blend of people and technology. I vaguely remember a P.J. O’Rourke quote (that I had to look up after as I write this) that came to mind: “Technology is dominated by two types of people: those who understand what they do not manage, and those who manage what they do not understand”. This guy is good, but today he had the look of the second type – shaking his head after admitting he was trying to make work some technology that he wished he’d understood better when he was on the floor of the last PackExpo in Chicago and decided to buy. He was wishing he’d have understood better what needs to happen in between production runs. I had a brief flashback. Sixteen-year-old me. First year of part time work and finally I thought I could get my own car with the money from that after school job. I had one picked out – front row of the lot (not a big dealer but the place with a trailer and a dozen cars or so.) My dad had stopped in to look at on his way home from work. Long story short – he was trying to tell me that I need to consider a few things it would most likely need and I’d have to pay for after I drove it off the lot. Things I hadn’t thought about - the hidden costs. Had I been in a job interview I’d have described myself as “Persistent. Confident”. My father would’ve described me differently. I was relentless and a pain. But he also knew I’d never learn and wasn’t listening, so he let me buy it. A week after driving it he and I were in the driveway replacing rear brakes. (Thankfully running a tab for me for the parts. His labor was free-ish. I was a captive audience for some thinly veiled “I told you so’s” as my payment.) Two weeks later the pinkish spots on the street where I parked had turned to a puddle and I learned that transmissions have fluid. Need fluid actually. And at the rate mine was bleeding out it could end up being parked there for a long time. Back to the co-pack floor as he opened up. “I do read the posts. I know that packaging people like me are working hard to figure out this labor gap. It hurts to see the economy steaming along and the volume that’s there for the taking, but I don’t have the people to do it. I also see that some of my peers, and competitors, are already adding robot arms into their lines. It makes sense. I don’t need to have all fifteen or so slots on this line automated. But if I can add in one or two arms on an understaffed line, I just raised my line productivity ten or twenty percent. And my capacity. And my bottom line gets better.” “Agreed.” I said. “So, this robot arm that’s not running now, when can I see it in action?”. “Tomorrow. Probably second shift”. “Mechanical issue? Broke down already?” “No, never had a breakdown yet. It runs well. It really does …WHEN it runs”, he told me. “So why not now?”. That’s when he shared the two things he wished he’d paid better attention to: time and skill level to changeover. “When I was at the show I should’ve dug deeper into programming time. We change SKUs on a line once or twice a shift. High mix is our world. On top of that the consumer packaging seems to change every few months – marketing keeps the look fresh but often that means I can’t just pull up from the saved library that SKU…it’s brand new. It’s faster than years ago, I get it. But for our products it still can take hours. If I could hire enough people, then the person in that spot I could train to do the task in minutes. That’s what I need from this robot…minutes not hours.” Across the aisle I saw his maintenance lead deep into what is called “unscheduled downtime” on the end of shift reports. Something stopped. And a dozen plus people standing idle until he and his team can fix it is making the site manager pay attention to that while we talk. “And that’s the other reason this robot is doing nothing right now. I need one of the maintenance team to get freed up and dive into the tablet to set up the robot arm’s next SKU. They are the highest skilled in the building, but I need them first to keep the floor running. So, there are times on a line where I have the product, the equipment and the due date hanging over my head… but I’ll be a shift or two behind because I need the robot programmed by a tech. What’s my choice? Let that line sit and all those people standing while he gets this one ready?”. He had a few other “lessons learned” but when I asked what he’d tell someone in his same shoes looking into adding robot arms to co-pack lines at their sites he said, “Do it. You don’t have a choice. After you get comfortable with the first couple, you’ll be adding robots into your next year’s budget like they were conveyors – just standard equipment that you need. Just be sure you pick one that can be programmed by people like a floor lead and not need an engineer or maintenance lead. And keep looking till you find someone that sells robots that can show you changeover times in MINUTES. I’m sold on robots. We’ll keep using this one. But I’m looking at better choices for the next one.” He wrapped things up with this. “Contract packagers live in a high changeover world. You always hope that the sales team will land that contract or you get that “big fish” order of one single part number that runs on one or two of your lines non-stop, day after day. But the reality is what you see here. Shortest changeover and the ability to have that changeover programming done by more people on your floor, well then technology like robot arms will let you make money and hit due dates.” “Make money and hit due dates”. That’s a way better mission statement than I’ve seen posted in many site lobbies. If you are looking for a robot solution for your co-packing operation – look at Southie Autonomy’s offerings. They have been using AI before artificial intelligence was being mentioned, it seems, in everyone’s marketing info here in early 2023 (It should remind you of when the iPhones, iPads, iPods, iTunes first came out and everybody’s product seemed to be being rebranded with an “i” in front of its name (looking at you iHeartRadio, iRiver, iRobot and many more). It matters because Southie’s solution, placed on any brand’s robot arm, does allow for changeover programming to happen in minutes. It does allow for a line lead to do it (vs a maintenance tech or engineer). You can contact them to learn more at info@southie.com. Unless you don’t want to “make money and hit due dates”. John has spent over thirty years learning in global manufacturing, automation, engineering, 3PLs and contract packaging. Currently still learning and sharing best practices in those fields and as an advisor to Southie Autonomy out of Boston MA.

From Concept to Carton: Robotics' Role in Transformative Co-Packaging Robotics integration into co-packaging represents a significant advancement, focusing on operational efficiency and precision. In 2021, a historic peak was reached with 517,385 new robotic installations globally, underlining a widespread shift towards automation. This development serves as a critical bridge, converting innovative design ideas into tangible packaging solutions. The packaging robots' market, valued at over USD 4 billion in 2022, is on track to expand at a CAGR of over 10% between 2023 and 2032. This growth is fueled by the efficiency, minimal maintenance, and longevity of packaging robots, leading to improved product quality and customer satisfaction. In this blog, we will explore the multifaceted role of robotics solutions, from transforming assembly lines to enhancing quality assurance. We’ll see how robotics is not just automating tasks but redefining packaging, bringing a blend of precision, innovation, and efficiency to the industry. The Robotic Assembly Line: Turning Concepts into Co-Packaging Reality Robotic assembly lines stand as a cornerstone in the co-packaging industry, turning concepts into reality. This process is marked by a series of critical steps where the advantages of robots, coupled with the synergy of technology and innovation, come to life. Let’s delve into the key aspects that highlight how robotics play a crucial role in materializing packaging concepts into reality: Design to Execution: Robotics efficiently convert detailed design plans into accurate physical packaging. This transition from digital blueprints to tangible products is critical in realizing conceptual ideas. Advanced robotics solutions can interpret complex design parameters, ensuring that the final packaging faithfully reflects the envisioned concept. Customization Capabilities: Robotic systems are programmed to handle a wide range of packaging designs, accommodating various sizes, shapes, and materials. This flexibility is essential for bringing diverse packaging concepts to life, allowing for quick adaptations to new designs without extensive manual reconfiguration. Scaling Production: One of the major strengths of robotics in co-packaging is the ability to rapidly increase production volumes. They can move products up to 20ppm and can work for around 70,000 hours (about 8 years) at a stretch. This scalability transforms small-scale concepts into large-scale productions efficiently, enabling businesses to meet market demands without compromising on the quality or fidelity of the packaging design. Integrating Innovations: As packaging concepts evolve, incorporating innovative materials or unique structural designs becomes crucial. Robotics solutions are adept at integrating these new ideas into the production process, ensuring that even the most avant-garde packaging concepts can be realized effectively and efficiently. Enhancing Product Handling: Handling delicate or intricately designed products can be challenging. Packaging robots excel in this aspect, packaging these items with high precision and care. This ensures that the product remains intact, and that the packaging concept’s integrity is maintained from start to finish. Quality Consistency: Consistency is key in co-packaging, especially when dealing with large volumes. Robots maintain stringent quality standards across all units, ensuring each package is a true representation of the original concept. This consistency is vital for brand image and customer satisfaction, as it guarantees that every product meets the conceptualized quality and appearance standards. Quality Assurance in Action: Robotics' Continuous Monitoring Robotics integration in co-packaging not only streamlines production but also plays a pivotal role in maintaining high product quality. This is achieved through a combination of advanced technologies and precise operational capabilities. Here's how robotics solutions contribute to robust quality assurance in co-packaging: Continuous Inspection: Equipped with advanced sensors and high-resolution cameras, robotic systems continuously scrutinize products on the assembly line. This enables the detection of any deviations or defects almost instantaneously, allowing for prompt corrective actions. Precision in Repetition: Unlike human labor, robots can perform highly repetitive tasks with unwavering precision. This uniformity is crucial in maintaining consistent quality across all products, regardless of production volumes. Data-Driven Adjustments: Throughout the packaging process, robots collect and analyze data. This information is crucial for making real-time adjustments, optimizing the production process, and maintaining a high standard of quality. Minimal Human Error: Automation significantly reduces the risk of human error, particularly in tasks that require high consistency. Robots execute these tasks with a level of accuracy that is challenging to achieve manually, leading to fewer quality issues. Efficient Feedback Loop: Robotic systems are often integrated with rapid feedback mechanisms. These systems enable immediate identification and correction of any issues, ensuring that the final product consistently aligns with the set quality standards. As we conclude, it's clear that the robotics integration in co-packaging is not just a technological upgrade, but a strategic shift towards smarter, more efficient production. Packaging robots are not just tools; they are collaborative partners that bring precision and innovation to the forefront of packaging. This evolution marks a new era where technology and human ingenuity join forces to create practical and groundbreaking solutions. The future of co-packaging, shaped by robotic advancements, promises not only enhanced efficiency and quality but also a platform for continuous innovation and growth in the packaging industry. https://www.linkedin.com/pulse/revolutionizing-industries-growing-role-packaging-robots-steve-jason/ https://automation.omron.com/en/us/blog/top-six-trends-shaping-packaging-industry-today https://www.robotics247.com/article/robots_edge_into_packaging https://www.cyberweld.co.uk/robotics-in-the-manufacturing-industry https://robotsdoneright.com/Articles/how-industrial-robots-improve-product-quality-in-manufacturing.html https://howtorobot.com/expert-insight/quality-control-robots-ensuring-excellence-manufacturers https://utilitiesone.com/the-role-of-robotics-in-enhancing-manufacturing-efficiency

The User's Voice: Shaping the Future of Humanized Robotic Interaction In robotics, the significance of human robot interaction (HRI) is increasing constantly with focus on a more empathetic and effective communication between humans and machines. In this blog, we will explore how user feedback is integral to refining robotic systems and their behavior, making them more intuitive, responsive, and aligned with human needs and emotions. We will discuss how ongoing feedback, personalization, and user-centric design are enhancing the functionality of robots and enriching the human experience with them. By exploring these key aspects, we will get a glimpse into a future where robots are not just tools, but empathetic, adaptive partners in our daily lives. User Feedback Loops: Iterative Improvements in Robotic Interfaces With the help of user feedback loops, robotic systems are not just becoming technologically advanced but also accustomed to human interaction. This ensures that as robotics progress, they do so with a deep understanding of human sentiments. Let’s explore the critical role of continuous feedback in refining human robot interaction: Iterative Learning and Adaption: Robots evolve through ongoing user feedback, mirroring the human process of learning and adapting. This continuous cycle of receiving and incorporating feedback enables robots to progressively refine their algorithms and behaviors. It ensures their actions and decisions are increasingly in sync with user expectations and real-world scenarios. Error Identification and Correction: Regular feedback helps pinpoint and fix errors in robotic systems, enhancing their reliability and functionality. By analyzing user interactions and responses, robots can identify discrepancies and malfunctions in their operations. This continuous process of error detection and correction not only improves the current performance of robots but also informs the development of more robust and error-resilient systems for future applications. User-Centric Design Philosophy: Feedback loops facilitate the personalization of robotic interfaces, increasing user satisfaction and engagement. These loops also ensure that robots are accessible and user-friendly, accommodating a broad spectrum of user needs and abilities. Refinement of Communication Methods: User feedback on non-verbal interactions allows robots to better understand and react to human gestures and facial expressions. Continuous input on voice interactions aids in the improvement of speech recognition capabilities, making conversations with robots more fluid and natural. Predictive and Context-Aware Adaptations: Analyzing feedback helps robots anticipate user needs and preferences, leading to proactive behavior modifications. Feedback is crucial in developing context-aware responses, enabling robots to adjust to different environments and situations effectively. Personalization in Robotics: Tailoring Experiences to User Preferences The journey towards personalizing advanced robotics is not just about technological innovation. Instead, it represents a shift towards creating more empathetic, responsive, and user-friendly machines. Let’s see how adapting robotic systems to align with individual user needs is beneficial: Customization of User Interfaces: Robots are being designed with adaptable interfaces that can be tailored to individual preferences, ranging from language settings to interface complexity. This customization allows for more intuitive interactions, particularly important for users with specific accessibility requirements. Adaptive Learning Algorithms: Robotic systems are increasingly equipped with algorithms that learn from user interactions, enabling them to adapt their responses and actions according to individual user behavior patterns. This continuous learning process ensures that robots remain relevant and efficient in meeting evolving user needs. Recognition of Individual Preferences: Advanced sensors and data analysis enable robots to recognize and remember individual user preferences. These include preferred temperatures in smart homes to packaging tasks on a manufacturing production line. This recognition leads to more personalized and satisfying user experiences. Emotional Intelligence in Robotics: Incorporating emotional intelligence allows robots to respond to the emotional states of users, adapting their behavior to provide comfort or assistance as needed. This aspect is especially crucial in healthcare and therapeutic settings, where personalization can significantly impact the effectiveness of treatment and care. Feedback-Driven Personalization: User feedback is continuously analyzed to refine and enhance the personalization features of advanced robots, ensuring they evolve in tandem with user expectations. This approach fosters a deeper bond between users and robotic systems, making them more than just tools, but companions that understand and grow with their users. Context-Sensitive Adaptations: Advanced sensing and AI enable robots to understand and respond to specific context of their interactions. This adaptability allows for assistance based on the environment, task, and user’s state. Such context awareness in robotics leads to more intuitive and appropriate responses, enhancing the overall user experience. As we look forward to the future of human robot interaction, the key to success lies in understanding and responding to the user. The advancements we see today in personalization and feedback mechanisms are just the beginning. Tomorrow's robots will be even more in tune with our needs, offering tailored assistance that goes beyond mere functionality. They will become an integral part of our daily lives, not only as tools but as intelligent companions that grow and evolve with us. This future, rich with possibilities, promises a new era where technology and humanity converge in the most seamless and enriching ways.

Beyond Assembly Lines: Navigating the Robotic Revolution in Co-Packing Robotics integration in co-packing industry has marked a significant shift from traditional assembly lines to automated packaging. The global packaging robots market is projected to grow at a CAGR of over 10% from 2023-2032. This growth is propelled by numerous benefits that robotic systems in packaging industry offer. These include efficiency, reduced maintenance, and increased capacity for high-speed operations for extended hours. Robotics revolution in co-packing is not just about automation. It’s a strategic response to industry challenges like rising labor costs and the need for precision and consistency in packaging. Moreover, companies implementing robotics have seen cost savings of up to 20%, a figure anticipated to reach 22% by 2025. This transition is not without its challenges. However, the long-term benefits, including operational efficiency outweigh these initial barriers. As we delve deeper into this topic, it's clear that the robotic revolution in co-packaging is not just about replacing human labor but about reshaping the landscape of manufacturing and packaging for a more efficient, precise, and sustainable future. Rise of Robotics: A Catalyst for Change Following factors are collectively influencing a transformative era in co-packing, where robotics is not just an option but a necessity for growth, innovation, and sustainability: Advancements in Technology: The continuous development in robotics technology, including improvements in AI, machine learning, and sensor technology, is pivotal. These advancements make robotics solutions more efficient, adaptable, and capable of complex tasks. Labor Market Dynamics: Scarcity of skilled labor and the challenge of repetitive or hazardous tasks in packaging industries drive the adoption of robotic systems. Robotics offers a way to mitigate these labor issues while maintaining production efficiency. Economic Drivers: Economic factors, such as the increasing cost of labor and the need for cost-efficient production methods, are significant catalysts. For instance, in 2021, the robotics industry witnessed a historic peak with an estimated 517,385 new robotic installations globally, indicating a significant shift towards automation in response to economic and labor market conditions Demand for Precision and Consistency: In the co-packing industry precision and consistency is crucial and robotic systems offer unmatched accuracy and uniformity in packaging, which is hard to achieve manually. Sustainability and Waste Reduction: The push towards sustainability has become a major driving force. Robotics solutions can help in reducing waste and optimizing resource use in packaging processes. This actively aligns with the global trend towards more sustainable practices. Integration with Industry 4.0: The trend towards smart factories and integration of IoT, data analytics, and connected systems in manufacturing processes are complemented by the robotic revolution. This integration enhances overall productivity and supply chain efficiency. Efficiency Redefined: Robotics Beyond Traditional Assembly Lines Transformation in the co-packing industry driven by robotic revolution leads to unprecedented levels of efficiency, quality, and productivity, paving the way for innovative and cost-effective solutions in the future. The following are ways in which the rapid adoption of robotic systems is taking the packaging industry beyond traditional assembly lines: Automated Pick and Place: Robotics solutions equipped with advanced vision systems revolutionize pick and place operations. They can handle products with speed, accuracy, and consistency. Packaging Line Integration: Robotic systems integrate seamlessly with various stages of the packaging process, enhancing workflow and minimizing downtime. High-Speed Sorting and Packing: Robots excel in rapid sorting and packing applications, ensuring precision and minimizing wastage. Quality Control and Inspection: Vision-guided robotics solutions in packaging enable sophisticated quality control, detecting defects, and ensuring high-quality output. Flexibility and Scalability: Robotic systems can be reprogrammed for different product sizes, shapes, or packaging formats. Hence offering adaptability to market demands. Worker Safety and Ergonomics: Automation of repetitive, physically demanding tasks reduces injury risks and improves workplace well-being. Data Analytics and Optimization: Robotics in packaging gather extensive data for analytics, helping optimize processes and improve decision-making. Beyond Assembly Lines - Embracing the Future of Co-Packaging with Robotics These future-oriented developments are set to revolutionize the co-packing industry, bringing unprecedented efficiency and innovation. Developing Smart Packaging Systems: Emphasis on creating packaging systems that are not only automated but also intelligent, capable of real-time decision-making and adjustments. Extended Reality Applications: Utilizing augmented and virtual reality in co-packaging for training, simulation, and enhancing the human-robot interface. Robotics as a Service (RaaS): Growth in RaaS models, offering flexible, cost-effective access to advanced robotic systems for businesses of all sizes. Nanotechnology in Robotics: Incorporating nanotechnology for more precise and efficient packaging processes, especially in sectors requiring extreme precision. Energy Efficiency and Green Robotics: Innovations leading to more energy-efficient robots, aligning with global sustainability goals. Predictive Maintenance Through AI: AI-driven predictive maintenance to reduce downtime and increase the lifespan of robotic systems in co-packaging. The future of co-packaging, backed by robotic revolution, promises to enhance operations and redefine packaging. And as we stand on the brink of a new era in co-packing, the integration of robotic systems paves a transformative journey. This evolution transcends traditional methodologies, bringing in an age where efficiency, customization, and sustainability are realities. https://www.wevolver.com/article/what-are-robotic-assembly-lines-history-components-advantages-limitations-applications-and-future https://alp.consulting/robotics-in-manufacturing-industry/ https://www.packworld.com/machinery/robotics/article/22869401/innovations-in-packaging-robotics-address-labor-crisis https://aithority.com/guest-authors/robot-revolution-how-is-packaging-needing-to-adapt-for-the-droid-generation/ https://blog.drupa.com/en/how-the-robotics-technology-revolutionizes-packaging/