How a Box Maker Solved Its Labor Problem with Robotics
Alliora is based in Fougères, a small town in the Brittany region of northwest France, where it makes boxes for clients in industries such as board games, cosmetics and champagne.
CEO and President Antoine Bruneau said Alliora had long wanted to automate its production lines. Unfortunately, its first experience was difficult. Industrial robots were too complex. The company bought one but never managed to make it work properly.
Meanwhile, the need for automation remained, as Alliora had to hire many temporary workers to meet seasonal demand. "Having a large number of temporary workers on the line can slow it down," Bruneau said.
That is not all: the work is physically demanding, and employees develop musculoskeletal disorders from repetitive tasks. "The boxes are quite heavy, and after a while your back starts to hurt," said Patricia Chevalier, Alliora's production manager.
The company needed something that would solve these problems but would also be simple to install and program.
The Alliora team did some quick online research and contacted Sterkelec, a local distributor of robot products and solutions. Sterkelec product manager Davy Puriot visited Alliora's production workshop. After discussing the problems they faced, he recommended automating the palletizing process.
Puriot recommended Robotiq's palletizing solution. It consists of a collaborative robotic arm from Universal Robots and a vacuum end effector. Because this solution allows end users to quickly create different programs, it was ideal for Alliora, which makes a unique product for each client.
Bruneau gathered his team, and Puriot demonstrated the solution. The team was thrilled. Bruneau immediately understood that this was the right solution for them. With Puriot's help, it was implemented quickly and easily.
Alliora production director Eric Blo said: "I am not a robotics specialist. I am not an automation engineer. But Davy Puriot explained it to me right away, and within 45 minutes I understood how the system works."
A few months have passed since the first Robotiq palletizing solution was integrated into one of Alliora's production lines, and it has changed the situation. Having a cobot allows Bruneau to hire two fewer temporary workers during peak periods, which helps stabilize the production line.
"Robots allow us to have smoother production lines, and that is exactly what we were looking for," Bruneau said. The production team also gives positive feedback.
“We wondered why we had not thought of this earlier, because it is such a huge relief for the staff”
Bruneau estimates the return on investment at 18 months, which is very fast. This successful experience is one he plans to repeat soon, deploying the Robotiq Palletizing Solution on three or four more production lines.
“Why automate palletizing first? Boxes weigh from 5 kg to 12 kg. It is a repetitive task, it is very heavy, and it is physical labor. People do not like doing palletizing”
Benefits of the Robotiq palletizing solution:
- Changeover. Three simple steps for all ISO-certified pallet sizes. Easily adapts to the production schedule, so the production line does not need to be stopped for several hours.
- Return on investment. Faster ROI (return on investment). How? Optimized, synchronized control of the cobot and axis motion delivers unprecedented cycle times.
- Deployment. Thanks to full compatibility between components, the customer gets a small footprint that fits existing floor plans. No external PC is required.
- Safety. Because safety is paramount, the company created an environment for safe integration and supports third-party safety devices.
Manufacturers are struggling to put robots to work in their factories because they are still too expensive and too complex. Robotiq's tools and know-how simplify the use of collaborative robots so factories can start production faster. Robotiq works with a global network of connected robotics experts, supporting its local manufacturers.
"Respect, honesty, integrity and responsibility underpin everything we do. We strive to keep all our commitments to ourselves, our clients and our partners. We solve problems with a positive attitude and find solutions. We keep looking forward to a world of possibilities! Simplicity is our close friend, allowing us to easily implement our solutions in an often complex world. We preach simplicity for sustainable growth and for turning our clients' challenges into simple integrated solutions," Robotiq said.
