Problem
An electronics parts manufacturer identified inefficiencies in the packaging process. Each shift required five operators, leading to high operational costs and frequent human errors. The process needed modernization to boost efficiency and reduce costs.
Goal
Automate the packaging process to increase output, reduce human error, and lower operating costs.
Story
In response to a growing volume of orders, the electronics manufacturer decided to implement packaging line automation. A robotic production line was integrated with the ERP system, enabling automatic transfer of packaging data to the logistics department.
The robot system fully automated sorting, packaging, and labeling – simple, repetitive tasks that were previously done manually.
After implementation, the company achieved a 35% increase in packaging efficiency. Eliminating the need for five operators per shift resulted in €58,000 (250,000 PLN) in annual labor savings. The return on investment came after just 14 months, and former packaging operators were reassigned to more advanced tasks, improving job satisfaction.
Results (KPI)
Thanks to the implementation, the company:
✅ Increased packaging efficiency by 35%
✅ Saved €58,000 (250,000 PLN) annually in labor costs
✅ Achieved ROI within 14 months
✅ Improved employee satisfaction by upskilling and reassigning operators
Project summary
- Identified packaging as a process for automation
- Installed a robotic packaging line integrated with the ERP system
- Fully automated sorting, packaging, and labeling
- Reduced human error and boosted process efficiency
- Achieved ROI and improved workforce engagement
Scope of implementation
- Robotic system integration with the production line
- ERP system integration for real-time logistics data transfer
- Packaging automation: robots performing sorting, packing, and labeling
Technology stack – core and supporting
⚙️ Collaborative Robots (Cobots): For repetitive packaging tasks
⚙️ ERP: Integrated with manufacturing and logistics systems
⚙️ SCADA: Robotic production line control system
