All types of businesses from all sectors of industry have a common denominator when it comes to the final stages of manufacture and production… How to get their product out there by the most economical means, considering both time and money.
End-of-line (EOL) automation services refer to the automation processes implemented in the final stages of manufacturing or production lines, designed to handle tasks such as packaging, palletising, labelling, inspection and logistics.
The aim of automation is to improve efficiency whilst reducing labour costs, enhancing safety and ultimately, ensuring consistency and quality for the final product.
Here, we’ll look at the key elements of this final and crucial piece of the manufacturing process.
Robotic Palletising and De-palletising
Automated systems use robots to stack finished products onto pallets in a specific pattern for shipping or storage, handling different product shapes, sizes, and weights to ensure optimal space utilisation and stability.
Robots also remove products from pallets for further processing or repackaging. De-palletising is commonly used in distribution centres and warehouses where products need to be unloaded from pallets for sorting or shipping.
Conveying and Sorting Systems
Automated conveyor systems transport products from one station to another and can be tailored to handle different product sizes and weights, then integrated with other automation systems for a more seamless transition process.
Automated sorting equipment then directs products to their appropriate locations based on predefined criteria such as size, weight, destination or packaging requirements. Sorting can be achieved through various technologies, including belt sorters, pushers or robotic arms.
Packaging Automation
Automated case packers arrange products into cartons or cases, sealing them securely for shipping. This process often includes different types of case packing, such as horizontal, vertical, wrap-around, and top-load.
Machines automatically place products into bags, wrap them in plastic film or shrink-wrap them for more thorough protection during transport.
Cartoning machines form, load, and close cartons around the products. This can include additional steps like adding inserts or printing labels directly on the carton.
Labelling and Marking
Automated labelling systems apply labels to products, cartons or pallets and can print and apply labels on demand, ensuring that each label contains accurate and up-to-date information such as barcodes, QR codes, serial numbers and shipping details.
Marking systems also use technologies like laser marking, inkjet printing or thermal transfer to directly mark products with the necessary information.
Quality Inspection and Control
Cameras and sensors are used to inspect products for defects, proper labelling and correct packaging. The systems can detect inconsistencies, misalignments or defects, triggering automated responses such as rejection or re-worked options.
Automated scales and dimensioning systems check that the products meet specified weight and size criteria, with any deviations from the acceptable range being flagged for correction.
Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs)
AGVs and AMRs transport products, pallets or raw materials between different areas of the production floor or warehouse and can be programmed to follow specific routes or navigate autonomously, avoiding obstacles and optimising travel paths.
Pallet and Stretch Wrapping
Automated wrapping machines apply stretch film around pallets to secure products during transport, which help to protect products from dust, moisture and movement during shipping and handling.
Data Collection and Reporting
End-of-line automation systems often include software for data collection and analysis which monitors production and error rates, downtime and other key performance indicators (KPIs), providing valuable insights for process optimisation.
Safety Systems and Compliance
EOL automation incorporates safety features such as light curtains, emergency stops and guarding systems to protect workers from potential hazards. Compliance with industry standards and regulations (e.g., OSHA, ISO) is also a key element.
Integration with Warehouse Management Systems (WMS) and Manufacturing Execution Systems (MES)
End-of-line automation systems are often integrated with broader WMS and MES to ensure seamless coordination between production, packaging, inventory management and shipping, aiding integration and optimising the entire supply chain process.
Pallet Handling and Stretch Wrapping
Systems designed for the automatic handling of pallets, including wrapping them for transport or storage, help ensure stability and protection during movement.
Traceability and Serialisation
Automation systems enable the tracking and tracing of products through barcodes, RFID tags, or other identification methods, which is crucial for inventory management, quality control and regulatory compliance.
Predictive Maintenance and Monitoring
Implementing predictive maintenance systems which monitor the health of automated equipment helps to pre-emptively address potential failures or breakdowns, in turn reducing downtime and maintenance costs.
Collaborative Robots (Cobots)
Cobots work in conjunction with human operators to perform repetitive or ergonomically challenging tasks, such as packing or inspection, without requiring extensive safety barriers. This collaboration helps improve productivity, whilst maintaining safety at all times.
In summary, end-of-line automation services encompass a wide range of technologies and processes aimed at optimising the final stages of production. All of the elements work together to enhance productivity, improve quality and ensure safety, ultimately leading to a more efficient and competitive manufacturing or production operation.