Richard Bloss

Automation pushes the envelope of postal mail handling efficiency

Purpose – The purpose of this paper is to review the impact automation is having on improving the efficiency of handling all types of mail.Design/methodology/approach – The paper presents information from in‐depth interviews with producers of postal automation equipment, visits to automated postal facilities and interviews of postal workers and individuals involved with postal automation over the past half century.Findings – All three major classes of mail: envelopes, flats and cartons (parcel post) are now handled almost entirely automatically, including even reading the address.Practical implications – Others with the need to handle large quantities of mail‐like items can see how automation has greatly increased the efficiency of handling such items.Originality/value – The paper provides an expert insight into how automation innovation continues to reduce cost, improve accuracy and speed the logistics of handling letters, packets or flats and cartons.

Smart robot that picks parts from bins

Purpose – To describe how one innovative company has developed software which teamed with a vision system allows an agile robot to be taught how to pick randomly place parts from a multi‐layered bin.Design/methodology/approach – Software, which runs on an industrial PC‐based computer platform, has unique algorithms, which can identify randomly placed 3D parts in a bin and calculate the path the robot needs to take to pick each part.Findings – The software has been successfully applied to picking many different part configurations, including odd‐shaped brackets, long slender vehicle axles, round brake rotors and cylindrical shaped pistons and other automotive housings.Practical implications – Vision‐guided robotic picking can now be more efficient and faster than manual part picking in many applications. Users need to rethink part picking.Originality/value – A long‐sought solution to quickly picking parts from bins is now a reality.

Maybe the world's largest automated assembly system?

Purpose – To examine how a very large order assembly system can be designed and commissioned to achieve a throughput of filling 2,400 order totes/h with medical prescription orders.Design/methodology/approach – To combine RFID and bar code scanning, individual pill bottle handling, pill dispensing, pre‐packaged carton dispensing with some computer directed manual operations were key to meeting a goal of automatically filling tens of thousands of line items per day.Findings – Combining automated pill dispensing with automated small item order filling and computer directed pick‐to‐light manual item picking results in a single integrated system. A careful design by experienced suppliers is important to achieving successful commissioning in a timely manner. Read/write RFID technology plays an important role in insuring accuracy and traceability of each prescription bottle.Originality/value – Shows that complex order filling applications such as the highly regulated medical prescription filling can be automate...

HARM type MEMS-based reed switch innovations address medical, automotive and other micro switching applications not previously possible

Purpose – The purpose of this paper is to review the advancements in development of high aspect ratio microfabrication (HARM) type of micro-electro-mechanical systems (MEMS) reed switch sensors for much improved performance in a much more compact package. Design/methodology/approach – The paper presents an in-depth review of a number of applications of HARM built MEMS reed switches and consultation with a manufacturer. Findings – One manufacturer has introduced a totally new way to fabricate reed switches which brings numerous benefits such as reliability, higher voltage capability, lower contact resistance and other features in a new tiny package. Practical implications – Manufacturers of devices needing the benefits of the reed switch concept but who need a much smaller and compact switch now have a new option to explore. Originality/value – An expert insight into how to solve reed switching problems where space is at a premium.

Innovations like two arms, cheaper prices, easier programming, autonomous and collaborative operation are driving automation deployment in manufacturing and elsewhere

Purpose – The purpose of this paper is to discuss how robot innovations as well as educational experiences are driving the more rapid deployment of automation into the manufacturing environment and other applications and reviewing the impact on employment. Design/methodology/approach – In-depth interviews with builders and system integrators of automation equipment and conferring with users of robotics as well as attendance at conferences and trade shows addressing these topics. Findings – Originally robots addressed only “heavy lifting” applications where cost and flexibility were very secondary considerations. Today users are looking to deploy robotic automation into all types of manufacturing and other applications where lower cost, two-armed flexibility and ease of programming are some of the very important considerations. Robotics are making manufacturers more competitive and growing thus creating more jobs, not costing jobs. Practical implications – Customers may be surprised at the automation innov...

Assembly and Automation Expo highlights innovations in automated assembly

Purpose – The purpose of this paper is to review the automated assembly technology at the Assembly and Automation Expo. While assembly is the feature show, it combines with manufacturing of electronics, plastics and medical devices at the same venue.Design/methodology/approach – In‐depth interviews with exhibitors of automated systems, system integrators as well as suppliers of related components motion elements, laser markers.Findings – Automated assembly continues to become more flexible, modular, as well as better suited for smaller lot orders and includes more real‐time inspection capabilities.Originality/value – The paper shows that new products to be assembled are driving those who provide automated assembly systems to create better solutions. These include solutions that are more cost‐effective, faster and include more quality assessment and tracking as part of the automation.

Automatically building or repairing composite fibre structures

Purpose – This paper sets out to report on the developments in the evolution of advanced composite fibre structure production systems, to highlight advanced equipment already in production and to examine efforts to extend automated technology to assessing damage and automatically repairing composite fibre structures.Design/methodology/approach – Leading companies in design and construction of advanced composite fibre production machinery are teaming with other technology leaders to further automate the inspection, damage assessment and repair of composite fibre structures. Automated control and movement of inspection scanners, coupled with computer analysis of findings, provide input to repair program generation. The repair program then can direct the ultrasonic cutting and composite fibre tape‐laying procedures necessary to complete the repair. Also important is the coordination of a material‐handling system to link the parts and the required production subsystems.Findings – The outlook for totally autom...

Automated carton making, order filling and goods movement lifts material handling to new heights of efficiency

– Review of the most recent Automate and Promat shows in Chicago with emphasis on the new automation innovations and applications on display. The paper aims to discuss these issues. , – In-depth interviews with exhibitors of automation equipment and system integrators of automation technology at these dual shows. , – Automation technology continues to address an ever increasing number of material handling applications. , – Customers may be surprised at the automation innovations and new applications which are appearing in the material handling environment. , – A review of some of the latest automation innovations and applications that one might have seen if they had been on the exhibition floor at the most recent dual Automate and Promat shows.

Automation meets logistics at the Promat Show and demonstrates faster packing and order filling

Purpose – The purpose of this paper is to review the Promat Show (material handling) and the Automate Show (robots and vision) run jointly in Chicago with emphasis on new automation innovations for packing and order filling applications.Design/methodology/approach – In‐depth interviews with exhibitors of material handling automation which addresses packing and order filling.Findings – Mobile robots have come of age with multiple vendors offering units for handling goods. Delta robots have found a niche in quick handling of packing and order assembly.Practical implications – Customers will have to begin thinking of mobile robots as much more autonomous and self‐guiding for goods handling in the warehouse. Logistics customers need to examine the abilities of the delta style robot to do more and faster picking and packing than ever before.Originality/value – The paper provides an expert insight into how automation innovation continues to reduce cost, improve accuracy and speed of logistics and order filling.

Automated assembly of electrical panel covers

Purpose – To report on the design and development of an automated circuit breaker panel cover assembly system. The system employs two robotically controlled spot welding heads and a robotic finished workpiece unloading station.Design/methodology/approach – A major electrical equipment builder turned to a skilled system integrator to design a system to meet a specific productivity goal and handle a wide family of product. The system integrator turned to several highly qualified subcontractors to supply key portions of the system. As a team then selected the welding heads, controls, pallet transport systems and robots and developed a system controller, parts holding devices and software for the application.Findings – A combination of some manually operations with automated spot welding and robotic workpiece handling equipment can produce outstanding productivity improvements.Practical implications – A careful selection of a qualified system integrator with experience in the type of application, teamed with ...