The Manual Mindset Needs to be Left Behind

Robot offline programming (OLP) technology can automate the planning and design of a new robot work cell in a virtual environment, enabling robots to help reduce material waste. © vizualni – stock.adobe.com

How manufacturers can steer their sustainability strategies in the right direction.

By Mikko Urho, CEO, Visual Components

In recent years, manufacturers have faced the dual challenge of needing to reduce energy usage and preserve natural resources, alongside ensuring their operations don’t negatively impact the environment. However, the economic strain on the sector has hindered progress. While the US inflation rate has headed in the right direction in recent months, the significant rise in 2022, peaking at  9.1% in June, has left a lasting impact on the prices of goods and services.

Through a recent survey, we discovered that due to these pressures, 32% of US businesses are not confident that they will help in the collective effort towards net zero carbon emissions. But everyone will need to play their part. In a little over six years, there needs to be a 45% reduction in emissions to keep global temperature increases limited to 1.5C above pre-industrial levels.

Packaging manufacturers are not immune from the challenge. They need to steer their sustainability strategies in the right direction, with potentially millions of items needing to be packaged to the same standard to prevent any waste. But with finances squeezed, wise investment in technology solutions is needed for a rapid ROI and environmentally friendly practices.

The Financial Squeeze

Economic circumstances have had a negative impact on manufacturing budgets and put the focus on environmental concerns on the backburner, but skills shortages have posed their own problems. The difficulty in hiring new talent, cited as one of the biggest challenges among 42% of organizations, is creating the need for higher salaries to be offered to the most skilled and experienced in the sector. According to further figures from the survey, all US companies have had to do this to ensure that key individuals don’t walk away and join a competitor.

Unreliable legacy equipment is also creating cost concerns. Over a third of respondents (38%) incur downtime of between $12,701 – $31,750 due to dated technology. Ineffective utilization of robots has also led 17% of survey respondents to report their organizations wasted between $31,751 – $63,500 due to a mistake when deploying them. With these kinds of figures finding their way onto the balance sheet, how can manufacturers even begin to allocate financial resources to sustainable practices?

Moving Away from Manual Programming

A proportion of manufacturers have made progress with their environmental strategies. In fact, 36% are taking steps to reduce their power usage, which has the combined benefit of reducing costs and making a positive impact on the planet. But legacy ways of working are counteracting these efforts in many cases, including the way in which robots complete tasks on the factory floor.

Take for example the tendency to manually program robots to complete packaging tasks. With human error always a possibility, these processes could be completed incorrectly due to inaccurate programming, leading to unnecessary material waste. Cartons, bottles, boxes and sacks could also be incorrectly assembled or tied, with costly rectifications needed before they move down the supply chain.

The Sustainable Possibilities

A manual mindset needs to be left behind. Robot offline programming (OLP) technology can automate the planning and design of a new robot work cell in a virtual environment. A robot can complete tasks to the highest accuracy and reduce the chance of any material waste being produced.

In the worst cases, it can be weeks before a robot is deployed due to lengthy manual programming. The ROI gained from immediate deployment of robotic applications with OLP means that goods can be packaged and sorted quickly without error, driving profitability and reducing costs. Programmed collaborative robots (cobots) can automatically detect the size of packages to be sorted into different lines, allowing ecommerce retailers to send out items to households quicker.

Increased revenue then allows reinvestment in sustainable initiatives. Finally, robots can be programmed from any location, reducing the need to travel and lessening the carbon emissions associated with commuting.

Part of the Wider Effort

Packaging manufacturers are at a pivotal point, balancing economic challenges with the need to meet global sustainability goals. Hurdles like inflation, hiring difficulties and the expense of outdated machinery have combined to sideline eco-friendly efforts. Yet the push for carbon neutrality is more pressing than ever.

Implementing technologies such as OLP can drastically reduce manual errors, waste and downtime, boosting ROI and allowing for more investment in green initiatives. With the deadline for significant emissions reductions looming, packaging manufacturers must shift from manual processes to automated systems to keep their sustainability strategies on course.

About the Author

Mikko Urho has had an extensive career at Visual Components, dating back to the year 2000 as a summer trainee. He became CEO on the company in March 2021. His vast experience includes direct sales, building a world-wide partner network, and managing reseller channels. He is well known and respected by many of Visual Components’ partners and customers around the globe. Learn more at https://www.visualcomponents.com.