CASE STUDY- FMCG INDUSTRY- GODREJ INDONESIA PROJECT
FMCG- Fast Moving Consumer Goods, is a vast industry. The primary packaging machines that are coming in the market are of high speed & one should not neglect the man power required at the end of the line to properly manage their production lines.
Existing process is a manual process where there are more than 8 people are working on the same line to cope up with the incoming line speed usually 120 Mono cartons per minute. The space requirement is also high & the shift workers are getting changed every 8-12 hours which results in slow end of line packaging & loss of productivity.
PRODUCTION CHALLENGES
High speed cartooning machine:
The proposed solution for pick & place of the Mosquito Repellent mono cartons inside the shipper carton was done at a speed of 120 Mono cartons per minute.
Product Stacking inside the shipper carton :
Customer wanted to have 3 layers of 8X6 Matrix inside the shipper carton
BUSINESS IMPACT
While manual packing is cheaper on "Day 1," the Cost per Unit increases every year due to wage inflation. With automation, the cost per unit stays flat or decreases as the machine is depreciated.
MAS SYSTECH SOLUTION
We supplied Robotic case packer to customer to cope up with the speed of incoming Mono cartons with the help of Yaskawa Robot GP 50.
CUSTOMIZATION APPLIED
We provided the solution inline with the current filling & Cartoning line. The Mono cartons with Mosquito Repellent are picked & place inside the Shipper Carton to provide unique solution to their manual handling problems. A single Robot used to form the corrugated box & for case packing as well.
INSTALLATION PROCESS
The installation of the such equipment is simple & easy to use. We Installed the whole setup in 14 working days.
The installed, commissioned & handed over to customer on 20th day.
CHALLENGES OVERCOME
1. Efficiency and "High-Tech" Advantages
Modern case packers utilize precision robotics and synchronized motion control to outperform manual speed and accuracy.
Consistency
Unlike human labor, a machine does not suffer from fatigue. It maintains the exact same throughput at 4:00 PM as it did at 8:00 AM.
Precision Placement
High-tech grippers ensure that Mono cartons are placed gently into cases, preventing "drop damage".
Data Integration
Automated lines provide real-time data on production rates, downtime, and reject counts, allowing for better inventory management.
PRODUCTION LINE DATA
The following table compares a standard medium-speed production line over a single 8-hour shift.
| Features | Manual Packing | Automated Packing |
|---|---|---|
| Throughput (Output) in BPM | 25-30 Mono Cartons Per Minute | 100-120 Bottles Per Minute |
| Staffing Required | 4-6 Operators | 1 Operator |
| Error Rate | 2-3% (Missed Mono cartons) | Less than 0.1% |
| Operating Hours | Limited by Breaks/Shifts | Continuous (24 X 7) |
| Annual Labour Cost | 4-6 Operators X Daily Wages X No. Of Days | Maintenance/Operator Cost |