Consumer Electronics Packaging Line

Our customer wanted to automate a previously manual packaging line. Although the manual line worked well, our customer was having quality control issues, and growing demand for the product was leading to problems meeting production numbers. ABCO was brought in to automate the line. Automating the line had the following benefits:

* Increased throughput
* Greater quality control
* Confirmation that all components were included
* Data collection

ABCO accomplished this by planning and building an entire packaging line. The Controls and Systems Integration Department developed the PLC, HMI, and networking systems that would be the heart of the packaging line. This included integrating an inspection system to determine if all of the components were included in the box, and incorporating an in-line check-weigher as an additional quality control measure. A bar-code scanner and a bar-code printer were also included in the line as well as all controls for the conveyor, case former, box opener, reject mechanism, etc.

Once all the pieces were in place, the entire line was setup and tested at ABCO. A case erector forms the box, and the box opener then opens the topside flaps so that operators have easy access. The operator then places all of the components into the box and presses a button to index the conveyor. The box then travels to the inspection station where sensors determine if all components are in the box. If all components are not present, a reject mechanism pushes the box off onto a spur conveyor where it can be taken for rework.

Boxes that pass the inspection station then travel over a check-weigher where the box is weighed as an additional check to ensure that all components are included. Any boxes that fail at this point are pushed off onto another spur conveyor for rework.

Boxes that pass the check-weigher continue down the line where a bar-code reader scans the label on the product. This data includes the serial number of the product, the model number, and date of manufacture. This data is stored for retrieval at a later date if necessary. The system sends the data to a bar-code printer, which prints an identical code and applies it to the outside of the box. This makes inventory and shipping easier.
The finished box travels through a case taper which seals the box. The package is now ready for shipping.

During the whole process, or Controls and System Integration Group worked with our customer to tailor the system to their needs. ABCO provided complete support during the installation and startup process. Including modifying controls and programming as necessary to accommodate changes in functionality requested by the customer. ABCO has built several of these lines for our customer, demonstrating our ability to meet and exceed their very stringent quality standards.