Achieving 24/7 Automation in Water Treatment Membrane Production

03/05/24 Achieving 24/7 Automation in Water Treatment Membrane Production

Background

In manufacturing, product identification is crucial for traceability and safety. Labels serve various purposes, such as indicating product names, serial numbers, lot numbers, manufacturing dates, and expiration dates. The automation of ID assignment is on the rise, driven by labour shortages and increased costs. Industrial robots are also playing a pivotal role in applying labels efficiently, replacing tasks that were once performed exclusively by human operators. This shift towards automation enhances efficiency and precision in the manufacturing sector.

Business Challenge

The customer, a water filtration manufacturer, faced significant challenges due to changes in work styles, evolving workplaces, an aging workforce, and a shortage of labour. These factors created a pressing need for factory automation to meet increasing product demand amid a limited labour pool. The objective was to implement a fully automated production line covering tasks from water filter membrane winding to labelling, ensuring continuous 24/7 operation and improved production efficiency. A critical challenge was integrating the newly automated processes seamlessly with the customer’s existing processes with a new RFID-powered management system.

Solution

SATO implemented an all-in-one labelling solution utilising two CL4NX units and a multi-axis robotic arm complemented by camera-based image recognition for label positioning, verification, and inspection. The incorporation of image detection and robotics ensured pinpoint accuracy in label application. As a result, the production line achieved full automation, operating around the clock without human error, interruptions during shift changes, or staff breaks. This system not only enhanced operational efficiency but also aligned with the company's sustainability objectives by bolstering productivity, minimising label and product waste, and fostering manufacturing process stability.

Results