Contributed by Southie Automation
Introduction
It’s 2033, what became of secondary packaging manufacturing as it grappled with the challenge of significant shortage of skilled labor in 2023? The implications were far-reaching, casting shadows of uncertainty over the industry’s future. However, amidst this pressing crisis emerged a beacon of hope: the relentless march of automation and robotics, which grew exponentially year after year.
Touring a Robotic Warehouse
We follow Jack, facility manager of Innovation Packaging Solutions, as he gives a tour to a group of robotic technician majors. It was evident that the machines now bore the mantle of responsibility previously shouldered by human hands – palletization, kitting, packaging assembly. The air buzzed with a different kind of energy—one driven by the precision and efficiency of these automated marvels whirling through the factory completing various tasks.
In a corner of the facility, we observed a team of collaborative robots, or cobots, flawlessly maneuvering amidst packaging materials. Their agility was much improved from ten years ago. A technician explained how these cobots had become the backbone of the operation by working as a team and dealing with unanticipated events without the need to be explicitly programmed to do so.
Their high flexibility and ability to handle various tasks in a warehouse compensated for the shortage of human workers. With their adeptness at pick-and-place tasks and their unwavering precision, these cobots seamlessly integrated into the workflow, ensuring production continued uninterrupted. Robots simply don’t get tired and have been adapted to integrate into existing and new processes without significant engineering to implement. This is the scene across packaging manufacturers across the world. Any facilities that didn’t adopt robotic technology didn’t last.
Filling in the Gaps
The specter of a labor shortage had also led to the proliferation of autonomous mobile robots (AMRs). These tireless entities glided across the factory floor, handling the transportation of materials and finished products with remarkable efficiency. It was a poignant reminder of the industry’s reliance on these intelligent machines to bridge the gap left by the dwindling human workforce. Companies like Southie Autonomy helped make the transition so effortless because they were able to effectively shorten the communication gap between robots and humans without the frustration of high-level coding. A higher number of contract packagers adapted robots to complete various tasks for multiple brands, amplifying efficiency.
As the tour delved deeper into the facility, we encountered the heart of the operation—the control room, where technicians, known as Robotic Managers, meticulously monitored screens displaying the intricate dance of machines. These individuals were the custodians of this automated symphony, ensuring that each robotic unit functioned harmoniously. Along with the screens they are using augmented reality (AR) to motion the robots’ controls.
Revolutionized, Not Replaced
The pressing need for automation had not only transformed the manufacturing landscape but also reshaped the roles of human workers. In response to the shortage, employees had undergone extensive training, transitioning into roles that demanded a deeper understanding of technology and robotics. Humans weren’t replaced by machines but instead elevated to a new type of workforce.
The conversation with these technicians illuminated a reality where automation was not just a choice but a necessity—a tool vital for sustaining operations amidst the scarcity of temp workers. Their narratives echoed a sentiment of empowerment rather than displacement, emphasizing how the integration of robotics had not eradicated jobs but had instead evolved them into more complex and intellectually stimulating roles.
Harmonious Team
The harmony of humans and robots was displayed in the employee breakroom of the facility, adorned with balloons and banners, celebrating the tenth anniversary of “Atlas,” one of the revered robots that had been an integral part of the packaging line since its inception.
The synergy between humans and machines was not merely a convenience but a lifeline for an industry navigating turbulent waters. The technological prowess of automation had become the cornerstone of survival, driving efficiency, and ensuring the continuity of operations in the wake of a daunting labor shortage.
Leaving the facility, one student pondered the significance of this revolution. The integration of automation and robotics was not just a response to a crisis; it was a testament to the resilience of innovation in the face of adversity. It was a narrative of adaptability and progress, where the convergence of human expertise and technological prowess paved the way for a redefined future—a future where automation wasn’t merely an option but an indispensable force driving the packaging industry forward.
Conclusion
While this may sound like something from ten years into the future, Southie Automation is currently implementing this type of workforce for their clients.
Two years ago, Brian Wagner of PTIS met Southie at a Contract Packaging Association event – and had to question whether their technology was real or maybe too good to be true. Advanced robots that can be quickly taught to do what humans do on a packaging line, leveraging AI, vision systems and mechatronics – at a similar hourly rate. And they can be easily moved from line to line and task to task, quickly reprogrammed and working long shifts, without breaks, never taking sick days. Imagine the possibilities.
With manual labor solved in 2024, weeks can focus on new challenges. What is your top opportunity heading into the new year? Contact PTIS to help you evolve your packaging opportunities.