Valvoline, a multinational company specializing in the production and marketing of lubricating oils and automotive products, implemented an automation solution at its plant in Dordrecht, Netherlands. The automation focused on the oil bottle packaging line, a critical process in its operation.
The Valvoline plant faced challenges in handling small product batches, as its main packaging system was designed for large volumes. Converting the system to accommodate small batches was costly and inefficient. Additionally, the manual process of loading and unloading bottles was slow and prone to errors, affecting productivity and the quality of the final product.
Valvoline identified the need for a flexible solution that could handle both large volumes and small batches without incurring high reconfiguration costs. Various automation options were evaluated, considering factors such as speed, precision, and ease of integration with existing systems.
An automated packaging system was implemented, incorporating the Yaskawa Motoman HP20F collaborative robot, specifically designed for packaging tasks. This robot, with a payload capacity of up to 20 kg and a reach of over 1.70 meters, is ideal for handling small and medium-sized items. The system also included the Yaskawa FS100 controller, optimized for picking and packing applications, allowing efficient real-time signal processing and easy integration with vision systems and PLCs.
The implementation was carried out by Overveld Packaging, a system integrator based in Hoogerheide, Netherlands. The process included the design, installation, and commissioning of the system, ensuring compatibility with Valvoline’s existing operations. The automated solution replaced the manual process of loading and unloading bottles, improving efficiency and reducing the possibility of human errors.
- Cost Reduction: The automated system allowed Valvoline to avoid the costs associated with converting the main system for small batches, optimizing resources and reducing operational expenses.
- Increased Production: The packaging speed increased significantly, reaching up to 40 bottles per minute, representing a considerable improvement in production capacity.
- Quality Improvement: Automation reduced human errors, ensuring greater consistency in the packaging process and improving the quality of the final product.
Kees Verbunt, project manager at Valvoline, commented: “The new robot line for packaging Valvoline oil bottles in boxes is specifically designed for use in the mechanical packaging system for large series. This means that the packaging speed of this new robot line does not have to be as fast. For us, the important thing is to have a packaging unit for small batches to avoid unprofitable conversion costs.”
Ad Nieuwlaat, production manager at Overveld Packaging, added: “Three years ago, Valvoline had the idea of acquiring a smaller packaging system with a maximum speed of 20 bottles per minute. The empty bottles would be manually placed on the conveyor belt and manually removed once they were filled. However, during the course of the project, the capacity increased to 40 bottles per minute. Since manual loading and unloading is no longer possible at this speed, Valvoline needed more automation, so they contacted us.”
The implementation of the Yaskawa Motoman HP20F collaborative robot in Valvoline’s packaging line allowed the company to efficiently address the challenges associated with small batch production. The automated solution not only improved efficiency and reduced costs but also ensured higher quality in the final product, positioning Valvoline as a leader in innovation within the lubricants industry.
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