Continuous Improvement in Manufacturing Processes: Robotic End-of-Arm Tooling

At Texecom, continuous improvement is more than a methodology-it’s a commitment to enhancing efficiency, quality, and safety across all our operations. A recent project in our moulding division, led by Peter Walker and Steven Wiseman, exemplifies this commitment through innovative advancements in robotic end-of-arm tooling (EOAT). This article outlines our journey from identifying areas for improvement to achieving substantial impacts on productivity, quality, and health and safety.

Why Continuous Improvement Matters

Continuous improvement initiatives are designed to optimise every aspect of the production process. In this instance, our objective was to automate manual operations on moulding machines that previously required dedicated operators. Our ultimate goal was to streamline production, enhance efficiency, and minimise health and safety risks. By integrating robotic arms and conveyor systems, we could improve the quality and efficiency of moulded parts while allowing operators to focus on more value-added tasks.

Project Scope: Automating the Moulding Process

This initiative focused on six of Texecom’s moulding machines, each of which traditionally required a dedicated operator. By fitting these machines with robotic arms and conveyors, we transformed the production process by automating part removal and machine resetting. The new system automates part transfer from machine to conveyor, reducing manual intervention and optimising operator utilisation.

Developing the End-of-Arm Tooling

One of the most challenging aspects of this project was designing and implementing custom EOAT for each unique part type. Each moulded part, varying in shape and size, needed a specific EOAT design to ensure safe and efficient handling. Led by Peter and Steven, the senior setting team took on this responsibility, creating and assembling the EOAT with custom adaptations, including:

• Air Snips: Integrated air snips precisely cut sprues from the mouldings, a task operators previously performed manually.
• Rubber Suckers: Fitted on tooling extensions, these suction devices protect the surface of the plastic and ensure a secure grip.
• Custom Extensions: Adjustments were made to the EOAT’s height and alignment for seamless part handling and transfer onto the conveyor. This setup was meticulously tested through several trials, ensuring precision, quality, and reliability at every step of the automated process.

Implementation and Results

After fine-tuning the EOAT setup, the project advanced to machine trials. The team verified the consistency and quality of the moulded parts, from removal to conveyor placement. With no observed quality concerns, the EOAT passed rigorous quality assurance tests, enabling a seamless transition from manual to automated operations.

The impact of this project has been transformative:

• Increased Productivity: The system now allows one operator to oversee multiple machines, significantly boosting output.
• Quality Consistency: Automated handling reduces the risk of human error, maintaining high product standards.
• Enhanced Safety: EOAT integration eliminates the need for operators to use air snips, a significant step forward in reducing workplace health and safety risks.

Future Plans

Building on the project’s success, Texecom aims to expand EOAT production to additional parts and machines. Currently, 28 EOATs are in production, providing a scalable solution to further streamline our manufacturing processes. This project is a testament to the power of continuous improvement at Texecom. By investing in innovation and empowering our team to find creative solutions, we continue to set new standards for efficiency, safety, and quality.