In the manufacturing industry, automation of production processes is progressing to address labor shortages and improve production efficiency. "Automated machines (automation equipment)" are pieces of equipment that automate tasks previously performed by humans, contributing to labor savings on production lines and stable quality. They are used in various processes such as product transport, inspection, assembly, and packaging, and have become an indispensable part of many manufacturing sites today.
This time,Focusing on the injection molding field, this article covers the basic roles, types, and benefits of introducing automated machines.I will explain in detail.
▼Key points of this article
- An automated machine is equipment that automates manufacturing processes that were previously performed by humans, contributing to improved productivity, stable quality, and reduced labor costs.
- Automated machines used in injection molding can be broadly divided into "front-end machines" that handle preparation before molding, and "back-end machines" that handle transportation, inspection, and packaging after molding.
- The benefits of introducing automated machinery include "increased productivity," "stable quality," "addressing labor shortages," and "improved safety."
- In particular, cleanrooms offer the benefit of reduced contamination risk.
- Sailor Pen's Robotics Division designs and manufactures automation equipment tailored to customer needs, based on its experience with over 3,800 automated machines.
▼Sailor Pen Robotics Division's automated machines
What is an automated machine?
An automated machine (or automated equipment) is equipment that automates manufacturing processes that were previously performed by humans.It is widely used in manufacturing facilities to improve productivity and quality, and to reduce labor costs.
Differences from industrial robots
Industrial robots are defined in Article 36, Item 31 of the Industrial Safety and Health Regulations as follows, and a key characteristic is the presence of a manipulator.
A machine having a manipulator and a memory device (including a variable sequence control device and a fixed sequence control device), which can automatically perform extension, retraction, bending, vertical movement, horizontal movement, or rotation of the manipulator, or a combination thereof, based on the information in the memory device.
While general-purpose industrial robots can handle a variety of tasks through programming, they may fall short of dedicated machines in terms of speed and efficiency when performing specific repetitive tasks that do not require a manipulator.
In manufacturing environments where a fixed process needs to be efficiently automated, automated machines designed specifically for that purpose are often the most suitable..
Benefits of introducing automated machinery
By introducing automated machinery, the following effects can be expected:
- Increased productivity
- Stable quality
- Measures to address labor shortages
- Improved safety
- Reduced risk of contamination
Increased productivity
Machines are often faster at repetitive, simple tasks compared to human workers.The amount that can be processed per hour increases.Furthermore, it can be operated 24 hours a day, significantly increasing processing capacity compared to operating only during the day.
Stable quality
Automatic machines repeat the same operation with high precision (repeatability: typically variation of 0.1 mm or less) according to set conditions.
With manual work, the accuracy and speed of positioning can vary depending on the worker's experience, skill, and even their physical condition on any given day, but automation can prevent such inconsistencies. For example, when inserting insert films into a mold by hand, misalignment and inconsistencies in pace inevitably occur.
On the other hand, by constructing a system in which film prepared by an insert film supply machine (automatic machine) is inserted into a mold by an extraction machine,High positional accuracyso,By inserting the film at the same time, a significant improvement in the quality of the finished molded product can be expected.
Measures to address labor shortages
In the manufacturing industry, labor shortages are a challenge, but by introducing automated machinery,Simple and repetitive tasks can be replaced by machines instead of being performed by humans.
In molding plants, it is necessary to remove molded products and sprues (unused parts that harden in the resin injection channel of the mold) from the molds of the molding machines. If this is done manually, even just the removal requires one worker per molding machine, and if inspection and packaging are also required, then three or more people are needed per line, and if shift workers are also considered, several times that number of people will be needed.
By replacing human workers with machines, one person can manage lines of several to dozens or more molding machines, resulting in a reduction of dozens of workers.
Improved safety
Automating tasks that involve danger or are physically demanding contributes to ensuring safety in those processes.
In the 1970s, the removal of injection-molded products was still largely done manually, resulting in hundreds of accidents each year where products were caught in the mold (estimated from documents 1-3). With the spread of automatic removal machines, the number of such accidents decreased, and is now almost zero (more than 9% of molding machines currently use removal machines).
Thus, by eliminating the dangerous task of removing the product from the mold in the injection molding machine, the safety of this process has greatly improved. Similarly,Automating tasks currently performed manually reduces the opportunities for humans to enter dangerous spaces, significantly lowering the risk of accidents.
Reduced risk of contamination
In production processes that take place in cleanrooms, such as those involving food, medical equipment, and precision machinery, it is essential to prevent contamination (contamination by dust, etc.) as much as possible.
In particular, the human body is a major source of contamination, including hair, dandruff, breath, and sweat. Therefore, minimizing the number of people, including workers, entering the cleanroom is crucial for maintaining cleanliness.
Therefore,Automating the production process inside the cleanroom reduces the risk of contamination caused by human error.
Automatic machines in plastic injection molding
Automated machines come in various types depending on the process and purpose for which they are introduced, and are generally designed according to the user's requests. In the field of injection molding, they can be broadly classified into front-end machines that perform preparation before molding and back-end machines that perform processing after molding.
Pre-molding machine
In the pre-molding process, preparation work before the product is molded is automated. In insert molding (a method of molding parts together with resin by placing them inside a mold), insert workpieces (such as labels or metal parts) are prepared to be embedded in the mold.
Label dispenser
In label insert molding, a device is needed to supply the label to the insert chuck of the removal machine before the label is inserted into the mold by the removal machine.
The label feeder picks up insert labels from a pre-set label stocker and transfers them to the label insert chuck of the extraction machine, adjusting the pitch to match the cavity position of the mold (i.e., the suction cup position of the chuck).
Automating the manual label supply process can be expected to reduce working time and improve positional accuracy.
Insert metal feeding machine
Similar to label inserts, metal inserts also require an insert metal feeder to prepare the insert workpiece (metal) so that it can be received by the insert chuck of the extraction machine.
These insert work feeders are typically used in conjunction with extractors, where the received labels or metal pieces are set into the mold using the same motion the extractor employs to remove molded parts.
Post-molding machine
In the post-molding process, tasks such as transporting molded products to the next stage, quality checks, and packaging can be automated.
In addition to cases where products removed from injection molding machines are processed, assembled, or inspected directly, there are also cases where work is performed separately from the molding machine, such as when assembling a large number of parts, including components other than molded parts.
Product Delivery
In a simplified system, after injection molding, the product is transported to the outside of the molding machine by a removal machine and placed on a conveyor belt installed next to the molding machine.
By extending the conveyor belt, it is possible to consolidate molded products from multiple molding machines, or to transport runners (unnecessary parts that have hardened in the resin pathways within the mold) to a separate room for crushing.
The extraction machine can be used to palletize products by shifting their positions, stack molded products on a conveyor belt, and even intermittently move the conveyor belt at specific intervals (number of shots) based on signals from the extraction machine.
Product inspection
The system automatically checks molded products for defects such as scratches, molding flaws, and misaligned insert labels using camera-based image inspection and electrical discharge-based pinhole inspection. If a defective product is detected, it can be separated from good products using an ejection chute.
Bag packing
This system automates the process of packaging products into bags and sealing the bags by heat. This can involve packaging each product individually, or stacking products before bagging.
Furthermore, the method of supplying bags is not limited to pre-packaged bags; sometimes, plastic sheets are sealed into bags within the machine. This not only improves the efficiency of the packaging process but also reduces variations in packaging quality due to individual workers.
Boxed
This process automates the task of placing finished products into boxes in specified quantities. The equipment varies depending on the shape of the molded products, the size of the boxes, and the packing method.
For example, there are cases where food containers are stacked up to a certain number of levels before being placed in a box, cases where they are arranged on a flat surface before being packed into a box with a sheet in between, and cases where items with special shapes are rotated each time before being placed in the box.
By installing both an empty box supply system and a stock system for packed boxes (actual boxes), long-term unmanned operation becomes possible.
stock
The amount of time an automated system can operate unattended depends on how frequently human intervention occurs before and after the automation process, such as the number of inserts supplied, the number of empty boxes supplied, and the amount of finished products stocked.
In particular, cardboard boxes packed by automated machines need to be stored somewhere until they are shipped by the next truck (or picked up by a person from the line), and a storage device (stocker) is a device that automatically stores these boxes compactly.
These machines often also function as empty box dispensers, supplying empty boxes to the product input location and then storing the actual boxes once the products have been placed inside.
Gate Cut
While the molded product is held in the chuck of the removal machine, the gate (the resin injection port portion remaining on the molded product) is cut using an air nipper or similar tool. Because gate processing can be performed simultaneously with removal, the gate cutting work that was previously done as a separate process can be eliminated.
Hinge bending
It's also possible to automate the hinge bending process for products that need to be folded immediately after removal, such as bottle caps. This not only reduces manual work in subsequent processes and improves the efficiency of the production line, but performing the hinge bending at a specific time immediately after molding while the product is still hot becomes a distinctive feature of the product and also improves its quality.
assembly
In the case of assembling multiple parts that include components other than molded parts, a separate automated assembly line may be installed in addition to the molding line.
Parts are supplied using parts feeders (devices that automatically align and supply parts), and a large assembly system is formed by incorporating not only plastic molded parts but also springs, tubes, and metal parts, as well as applying grease and performing various inspections.
semi-automatic machine
Automation isn't always the best solution; in many cases, it's more rational for humans to perform the tasks from a cost and efficiency standpoint.
In such situations, there is the option of semi-automation, which involves automating some of the tasks that would normally be performed by humans. For example, a human could set up the parts in the machine, and then the machining process for those parts could be performed automatically.
Automating the setup process is considered when it is not cost-effective in terms of installation space or production volume.
Points to note when introducing automated machinery
While there are many advantages, the following points should be considered when introducing automated machinery.
- Initial costs and cost-effectiveness analysis
- Responding to changes in products and production conditions
- Ensuring a maintenance and support system
- New sources of hazards and contamination
- The need for new skills and education
Initial costs and cost-effectiveness analysis
Introducing automated machinery requires an initial investment. It is important to consider the cost-effectiveness, taking into account the reduction in labor costs and the increase in production volume.
When installing equipment, it's advisable to consider utilizing subsidies and tax deduction programs offered by the national and local governments, as these may be applicable.
Responding to changes in products and production conditions
Because automated machines are custom-designed to suit specific products and processes, adjustments or modifications to the equipment may be necessary if the product shape or production conditions change.
To ensure long-term use, it's crucial to choose a manufacturer that can accommodate modifications and customizations after installation.
Ensuring a maintenance and support system
Regular inspections and maintenance are essential for the long-term, stable operation of automated machinery. Choosing a manufacturer with a robust post-installation support system can reduce the risk of equipment downtime.
New sources of hazards and contamination
Historically, the introduction of mold removal machines has dramatically reduced accidents involving objects getting caught in molds, but on the other hand, accidents involving industrial robots have occurred.
Regarding automated equipment, it is essential to recognize that machines, which are generally stronger than humans, are made of metal, and move at high speeds, making them extremely dangerous. Therefore, risk assessment and safety measures based on the three-step method (three steps to risk reduction) are indispensable.
Furthermore, while introducing automated machinery into a cleanroom reduces the amount of human movement, it becomes necessary to consider and implement countermeasures against sources of contamination generated by the automated machinery, such as dust from the sliding parts of the equipment and exhaust.
The need for new skills and education
If the assembly worker is replaced by an automated device, for example, completely different skills will be required.
While the person in charge is familiar with the work procedures, the equipment itself requires daily maintenance and adjustments, which necessitates reskilling of the person in charge.
Features of the automated machines in Sailor Pen's Robotics Division
Sailor Pen's Robotics Division designs and manufactures automation equipment tailored to our customers' needs. Automating manual tasks not only contributes to improved productivity and quality, but also to enhanced safety and reduced environmental impact.
Finally, let me introduce the features of the automated machines from Sailor Pen's Robotics Division.
▼Sailor Pen Robotics Division's automated machines
Design tailored to your needs
Sailor Pen's Robotics Division manufactures a variety of automated machines that are responsible for factory automation.We have met the needs of over 3,800 diverse manufacturing sites by providing custom-made solutions tailored to our customers' products, production lines, and installation environments.
We can also handle implementation into existing lines and process improvements.
Supports comprehensive automation
To successfully implement automation, it's crucial to design the entire production line, taking into account not just individual pieces of equipment, but the entire manufacturing process.
At Sailor Pen's Robotics Division,We offer a complete automation solution for plastic injection molding, from pre-processing to post-processing, and even independent systems.
Summary
Automated machines are equipment that automates manufacturing processes that were previously performed by humans, and they are useful for improving productivity, stabilizing quality, and addressing labor shortages.It is used in a variety of situations in manufacturing sites and plays an important role in building efficient production lines.
Based on our experience with over 3,800 automated machines, Sailor Pen's Robotics Division designs and manufactures automated machines tailored to our customers' products and production lines.We welcome inquiries even if you're just at the stage of wanting to discuss whether this process can be automated.If you are considering automation, please feel free to contact us.
▼Sailor Pen Robotics Division's automated machines
Reference:
- Ministry of Health, Labour and Welfare (formerly the Ministry of Labour), "Statistics on Occupational Accidents (Report on Worker Injuries and Illnesses)" (Annual editions from the 40s to the 50s)
- Japan Industrial Safety and Health Association (JISHA), "Status of Occupational Accidents and Safety Measures in the Plastics Manufacturing Industry"
- Japan Industrial Machinery Manufacturers' Association, Safety Committee, "Report on Safety Measures and Accident Statistics for Injection Molding Machines, etc." (Published in the 50s)
