The Coronavirus pandemic has altered all facets of our lives, right from how we work to how we lighten up. There are many propositions of this, including the likelihood for long-term and, in some cases, an everlasting amendment to business and technology processes. As per Gartner’s latest survey, merely 12 percent of the respondents consider their businesses are highly equipped for the impact of Covid-19, and the majority anticipate the pandemic to upset operations for the projected future.
So, if automation turned manufacturers across domains redraw their assembly lines, the effect of pandemic is making them focus on the shop floors to meet wellbeing and safety protocols with social distancing measures.
In this particular blog, we will study some of the enterprise implications of Covid-19 and what significant steps organizations can take to mitigate them. Further, this post will look specifically at social distancing and the role of automation solutions powered by Shubham Automation and how it can enable organizations without hampering productivity.
As further discussed with Biren Patel, Marketing Director of Shubham Automation, he said “earlier automation was looked as a tool for killing jobs, however, today the scenario is different as now automation solutions are enabling professionals to eradicate mistakes and errors, better follow industrial benchmarks, health standards, facilitate social distancing and maintain hygiene to improve the seamless flow of supply chain”.
Let’s further explore in detail about how automation solutions are enabling manufacturing and other industries.
How Shubham’s range of Automation Solutions assists Organizations Automate Processes
Shubham’s range of automation products lends a hand to companies automate their varied processes that allow the company’s stakeholders have more free time and a peaceful mind. This scenario also helps employees stay at a distance and don’t form groups to run a particular manufacturing job. It also helps them focus on producing more hygienic products, with expansions and more revenue sources, instead of spending time over physical labour.
Shubham’s automation solutions drastically reduce human errors, boost profits, and now also take care of social distancing.
1. Print N Apply: Error-free Technology Eliminating Pains
In the current time, stamping and serialization play a massive role in the product markets. To precisely print information that matches the product and applies the same at the correct place is a highly responsible job that cannot be left to physical labour, leading to violation of social distancing.
Automate this with Shubham Automation Print n Apply and make sure a seamless, error-free passage of products with correct information printed and applied on the product surfaces. This application works on several surfaces and categories of products, ensuring multiple usage patterns.
2. Mix Up Prevention: Reducing Human Errors and Boosting Profits
Imagine the shock of discovering a wrongly labelled product, leaflet or carton in the packaging process by a stakeholder or a customer? It would be a company and a brand killer. This scenario can simply be avoided if the manual sorting has been automated with the Mix Up Prevention Machine by Shubham Automation, enabling social distancing.
3. Automated Sticker Labelling Machine
Labelling pains come in diverse forms, sides, and sizes. Top labelling, side labelling, bottom labelling, or secure labelling diverges from your industry’s requirement. However, the pain stays the same. Shubham Automation strives to get rid of the same for you once and for all, with its wide variety of products.
Should you require twin labelling, tri-labelling or simple top or bottom labelling Shubham has the right applicators for you? Eradicate your label application pains and partner with Shubham Automation by investing in its automation products and following processes related to social distancing.
4. Automated Leaflet Pasting Machine
Pasting on top of containers, bottles, and larger surfaces have always been a complicated manual job. With Shubham Automation’s Leaflet Pasting machine, it has turned effortless, swifter, and accurate. So, invest in Shubham’s leaflet pasting machines and do away with physical error-prone labour jobs of pasting and also support social distancing.
5. Dynamic Checkweigher Solution
Shubham’s Checkweigher safeguards your product from precision pains and your brand from credibility losses. Blend with the advanced software that not only combines the swiftness and accuracy levels but also offer in-depth analysis which can assist solves quality, hygiene and social distance challenges at the shop-floor level.
6. Pick N Place Solution
If you have entirely automated manufacturing lines but have human resources or labour to check-out the packaging, there could be mistakes, compromise in social distancing and even have an effect on product hygiene. However, through our ROBO Pick N Place Solution with powerful scan mechanism it enables multi-faceted technologies interacting with automation to eradicate human errors and any of the compromises in maintaining product hygiene. The solution has a unique setup to identify and pick & place the products in the right packaging lines. This solution can also assist with layer-wise packing of bottles again enabling social distancing and hygiene of products.
7. PCC ACCURA
Shubham’s automated vision inspection solution PCC ACCURA acts like a smart eye checking-out the final packaging information on products to sustain information accuracy rather than depending on human resources to carry out this job manually, which even assists in resolving hygiene and social distancing issues. Further, it boosts line accuracy and quality assurance avoiding recalls, trimming down downtime, false-rejects, and minimizes any rework, and thereby continuously increases production line efficiency.
Check weighing is significant for manufacturing companies delivering quality products and want to facilitate customer contentment. A Checkweigher Solution is an integral part of the quality control system, making sure that each product that passes through a production line is of the precise weight to go into the market.
On the other hand, vision inspection solutions offer you an exclusive inspection performance for different types of FMCG and other industry products. The vision inspection system checks labels at the top and/or bottom side for their existence, right position, explicit content, and intactness.
Key Problems Faced by Clients in the FMCG Sector
- Due to the random sampling process of Bottles for weight checking at a specific time, there is no precise control on give away
- Bottles with underweight or overweight can even enter into the market which affects the brand image of the company
- There can be mix up of bottles on the packing lines which can cause distribution troubles
- The bottles can go missing in a carton, outer box and final shipper creating deliverable issues
- Bottles with smudged of cut printing and without printing can be released causing problems in the supply chain
- The compliance with net contents benchmarks can be compromised which can create regulatory challenges
- Other challenges include hygiene, safeguarding, and security of products
Blending of Bottle Check Weigher and Vision Inspection Solution by Shubham Automation
The new combination of bottle Checkweigher machine and vision inspection system by Shubham Automation blends the two operations of automated weight checking and vision inspection into one machine unit. The combination facilitates bigger inspection areas and numerous inspections at the same time. The new blended system even saves the overall floor space in the factory set-up and total equipment cost by merging the two vital operations. It also helps in releasing more batches of products swiftly.
The hygienically designed system by Shubham Automation uses advanced software, which delivers accurate analysis of high-resolution images. The high-performance software provides exact weight measurements at higher speeds.
Shubham Automation’s vision inspection system makes sure that products continually meet manufacturers’ quality benchmarks and specifications resulting in precise product presentations every time. And Shubham’s Hi-Speed Dynamic Checkweigher solution makes sure 100% quality control as well as trim down costly giveaways.
How Bottle Checkweigher + Vision Inspection Solutions are effectively used?
Useful applications of this blended solution include
- Automated checking of weights for finding underweight and overweight bottles
- Classifying and arranging bottles into diverse weight zones like underweight, overweight or specific weight zone
- Inspect linear barcode and product code to check mix up prevention
- Verify overprinting, make sure of precise product presentation, verify packaging and labelling integrity
- Offer tamper-evident sealing, detect physical contaminants and inspect contents inside the closed package
Shubham Automation Facilitating Automation and Quality Assurance Solutions
Shubham Automation enables a diverse range of automation and quality assurance solutions. The procedure initiates with automated washing, air-jet cleaning, sealing, filling, capping, labelling, coding & vision inspection, and mix-up prevention. With Quality Assurance Solutions, Shubham assists organizations in facilitating Pesticides, FMCG, Food & Beverages, and Pharmaceutical industry products in putting off errors, defects, and product issues so that the end consumer has the accurate product in his hand.
Following these processes advanced automation procedures such as Pick and Place, Automated Print and Apply, Automated Labelling & Pasting, and Tracking of products with comprehensive reports and analytics are enabled for automatedly as well as precisely weighed products.
Project: Bottle Check Weigher and Vision Inspection Solution
Shubham Automation recently received a full-size project of a combination of Bottle Check Weigher + Vision Inspection Solution from one of India’s leading FMCG companies. The company is manufacturing an extensive range of Fabric Conditioner & Softener bottles and had a combined requirement of a bottle Checkweigher and Vision Inspection solution.
Shubham Automation will be an integral part of the quality assurance team to produce this range of Fabric Conditioner & Softener bottles with this big-sized organization across India. These assortments of products will meet the highest quality standards, which will be further accessible across the country in different packaging.
Bottle Checkweigher solutions come in use in any of the FMCG, Pesticides, Pharma, or Food & Beverages packaging facilities to make sure bottled product is up to the yardstick weight and better-quality through this effective quality assurance procedure.
The combined solution can meet the demands of accepting large package sizes, more significant inspection areas, and multi-faceted inspections. Manufacturing companies can get precise assistance from Shubham Automation’s Quality Assurance and Automation Solutions to reduce costs, increase customer contentment, have hygienic products, and enable the supply chain.
With COVID-19 caused downturn, the upfront costs related to new equipment and employee training can increase. However, at the same time, hygiene and quality needs are growing too for entirely safeguarding the end-product users – stressing the importance of Automated Packaging Lines.
The automated packaging technologies make it simpler than ever to automate manual procedures and offer human contact-less products. Further, companies are looking to accomplish more with their automated machinery investments to deliver an extensive range of quality products.
And these products need to be fully hygienic, accurate, not at all contaminated or affected by any virus to make a far-reaching supply chain and productive packaging lines. Here is more about automated packaging lines and how they can offer benefits to end-product users.
1. Role of Automation and Quality Assurance Solutions
In the past, automation solutions were not always fit enough to completely automate all the tasks of overseeing quality control in the packaging line. Rather, the tiresome and recurring works of inspecting all products were left to human workers.
Now, with the development of innovative automated technologies, companies can get equipped to “see” and “catch” nearly 100% of errors. Meanwhile, Quality Assurance (QA) Solutions work diligently, which means the automation capabilities to catch the mistakes and act on it are advantageous, valuable, and swift to process. Blending with other automated equipment in the packaging procedure; this offers highly reliable packaging and better hygiene for end-product users.
2. End-to-End Quality Assurance throughout Supply Chain
In the past few years, product manufacturers used to just focus on the final products and their quality attributes. However, today quality assurance is in every stage of product development starting right from the manufacturing plant to the diverse phases of the supply chain to eCommerce and other selling channels and finally received by the end-product consumer. The hygiene is facilitated and positively kept in control throughout the channels keeping products safe, secure as well as sound.
3. Lack of Personnel or Human Resources drives Automation
Today it is exceptionally tough to find appropriate personnel and skilled human resources at fitting costs. Principally if less repetitive tasks and activities are involved. It is for these grounds that today not only more prominent companies, but even SME’s are faced with the query of meeting the day to day needs resourcefully and cost-effectively.
Lack of personnel is one of the most significant factors causing companies to accept and move towards automation. Rising human resource costs due to the intense competitive situation are having a greater impact on the supply chain and increasing the product costs for end-users. However, by automating the processes, you can reduce the overall costs of your products benefiting the end-users.
4. Reliable Monitoring, Tracking and Scaling with Quality Assurance Solutions
The areas of use for automation solutions within the packaging processes start from product Infeed to loading right up to primary product inspection and secondary packaging at the end of the line. One part of the procedure, which can unquestionably be automated prudently, is monitoring and inspection of the products. If the human element is still utilized for all these activities when it comes to quality assurance of the products, with manual weighing, packaging, and labelling, it is not possible to scale your production lines.
Even random sampling is more probably inadequate to meet the statutory requirements and can’t eventually assure consumer safety. This scenario is because the quality assurance requirements are incredibly complicated, particularly in the FMCG, Food, and Pharmaceutical industry. The product and packaging have to be steadfast as per the benchmarks when it comes to quality checking to enable end-users.
5. Facilitating Automation, Quality Assurance, and Track & Trace Solutions
Facilitating automation initiates with automated washing, air-jet cleaning, sealing, capping, labelling, coding & vision inspection, mix up prevention, automated weighing, pick & place, automated printing & applying, pasting, and tracking products with inclusive reports through automation-based solutions.
Coming back to Quality Assurance Solutions, they help companies in preventing errors, defects, and product issues so that the end consumer has the right product in his hand.
On the other end, Track & Trace Solutions ensure that each shipment is within the company’s knowledge, each batch is tracked as well as traced, and the company has the absolute grasp of their products for users from anywhere across the world.
To maintain and sustain hygiene, companies will invest in automated packaging lines and upgrade the existing ones with automation in diverse industry mix depending on their product users.
Product and packaging transformations will be seen in all market segments covering the major ones which are Food, FMCG as well as Pharmaceutical domains, which are directly driven by the consumer’s requirements of quality, convenience, hygiene, and sanitation.
One of the most prominent technologies in this digital era is automated eCommerce. It is a sufficient force that enables entrepreneurs to save time, money, efforts, and resources. In due course, it provides an exceptional opportunity for online businesses to scale exponentially.
Today, in the lock-down period due to disruptions caused by COVID-19, consumers expect swift, frictionless product transactions with visibility and accessibility at each step in the eCommerce supply chain.
How Automation can manage the current Demand-driven Marketplace
In this demand-driven marketplace, due to lock-down and moving ahead, the objective of the manufacturers is to hygienically and economically manufacture their products. This scenario needs reconfigurable, advanced machinery that can mix and match several product flows. And one solution for this comes in the form of supple automation solutions by Shubham Automation.
However, technology suppliers are taking the notion of flexible manufacturing a stage further by integrating independent applications, such as robotics, vision techniques, printing, and labelling with automated machine controls. They are also enabling processes, like automated weighing as well as automated printing & applying, along with tracking products using automation-based solutions.
Also, with the development of innovative automated technologies, eCommerce companies can get equipped to figure out nearly 100% of errors. In the interim, Quality Assurance (QA) Solutions work meticulously, which means the automation abilities to catch the errors and act on it are quick to process.
Integrating the Automation Portfolio in the eCommerce Ready Factory
Robots are a significant component in the eCommerce ready factory. The manufacturing sites are focusing more on automation and digitization, from suppliers to customers facilitating a response to omnichannel retail.
As an integral element of that effort, Shubham Automation has mechanized the subsequent steps of its automated processes by the Pick & Scan mechanism with its advanced Robo device. This technology comes with a one-stop solution for all sizes and categories of package scanning for consumer packaging products.
Further, on facilitating eCommerce expectations through Automation, Biren Patel, Shubham Automation’s Director – Sales & Marketing says that “As we move forward to enable eCommerce domains, we have altered the way we look at manufacturing automation and robotics.” He adds that “At Shubham, they are focusing on doing more integration and customizations like setting-up multiple diverse products in a single set-up, enabling advanced Robotics and hence they are putting efforts to boost the amount of automation and build agility right from when the order is being placed to when it is actually shipped in the eCommerce supply chain.”
As we discussed above, Shubham announced the launch of its innovative Robo device, which is known as Robo Scan, resulting in the integration of robotics and automation into one system. This scenario means there is no requirement for an added control cabinet for the robot, and that programming robotics and machine control is blended into one single developed system.
The Significance of Automated Labelling
An eCommerce package can pass through 15 to 20 diverse touch points in the supply chain ahead of reaching its destination. Tracking the individual packages to make sure the product is delivered all in one piece is a vital part of the eCommerce journey.
So, when an industrial product comes off the manufacturing line, it needs information on its origin and expiration dates. From here, many layers of information are being added to the packaged product. Every movement needs yet another labelling step. So there is a requirement of automating processes, which includes labelling at different places, whether it is enabled directly on the manufacturing floor or into the warehouse.
The Implication of Automated Sorting and Printing
Sorting and printing is an integral part of the supply chain infrastructure. Any product that moves in, around and out of the infrastructure has to be well sorted and have a label on it with a barcode or RFID tag. So, you can keep track of these products where they are going to assure the set requirements.
During production, barcode label systems recognize and track products as they move throughout an assembly line. And in the warehouse, these systems are utilized to mark racks, bins, shelves, and to categorize finished products.
This degree of flexibility and mechanism can be carried throughout the application areas right on the production line, such as automated printing, applying and labelling.
So, manufacturers are turning to technology providers to add flexibility for their production, packaging, and supply chain procedures. Primary product and packaging transformations will be seen in market segments like Food, FMCG, and Pharmaceuticals. These sectors are directly driven by the consumer’s needs of higher quality, convenience, hygiene, and sanitation, especially now due to disruptions caused by COVID-19.
The flexibility within the manufacturing and supply chain processes will get integrated flowing through automated weighing, packaging, labelling, and printing on goods, where enablement of essential eCommerce operations comes into the picture.
The disruptions caused by COVID-19 are directing manufacturing companies to tap automation and enable Robotic supply chains. The pandemic is quite instructive that the global supply chains that bring us many of our products have weakened in the process. The utilization of programmable industrial robots will increase and solve many problems to produce the products that we use.
So, what are the Supply Chain Solutions to Fight Disruptions like COVID-19?
As of last fall, most of the manufacturing companies reported unoccupied jobs, owing in large part to a gap between the skills companies required and the skill-sets employees had in the recent scenarios.
“So, if workers aren’t accessible, one alternative is the enablement of robots and automated processes that can support the supply chains by tapping automation for the post-pandemic world.”
How Software can enable Workers to Program Industrial Robots for Manufacturing Tasks
There are specific software and hardware devices to facilitate industrial robots. The software assists workers with little to no understanding of robotics to programming industrial robots for performing different manufacturing processes and activities.
With tailored robots, manufacturing companies can use them for custom runs, blending up with what they manufacture currently.
The Robotic Supply Chains Solutions – Robo Pick & Scan Mechanism by Shubham Automation
The team at Shubham Automation has mechanized the next steps of its automated processes by the Pick & Scan mechanism with its innovative Robo device, which is known as Robo Scan. This Robotics based smart aggregation system secures and makes the aggregation process seamless. This technology comes with a one-stop solution for all size and type of package scanning for consumer packaging goods and pharma industry.
By complying with stringent international guidelines governing the industries, Shubham’s Track & Trace Solutions directly collect and verify serialized information right on the primary package and the label. The entire system easily integrates with Shubham’s Smart Tracker Software and other third-party software.
Pick & Place Steps that are Enabled by Shubham Automation’s Robotic Systems
The bottles are discharged and the Robo picks & places the bottles in the shipper box as per the laid down matrix, which best fits in bulk packing line. The Robo can even place the layers in the box and fill the bottles in the set box automatedly. The further change part and other customizations can be applied for scaling the mechanism as per customized requirements.
Enablement of the Scanning Processes by Shubham’s Team
Shubham has introduced a single high-resolution smart camera-based technology that captures and reads all 2D codes of the stack in the field of vision to enable multiple code reading. Once the bottles are in accordance with the pre-set production process, a parent-child relationship is created, and the box is further labeled using the TTO type printer both manually or can be automated through our Print and Apply solution.
Key Benefits of the Robo Pick & Scan Mechanism comprises
- End to End Automation
- Innovative and Swift Processes
- Highly Accurate Procedures
- Free from Manual Errors
- Highly Robust and Scalable System
- Fits as per Client Requirements
- No Human Touch-points Involved
All these automation-based transformations were already in process and underway previous to the pandemic. However, COVID-19 is now accelerating them swiftly. So, the future outlook of supply chain infrastructure will be persistent in recovering the slowed-down economy through automation and by enabling Robotic supply chains in a quick time.
The Coronavirus pandemic is speeding up the rise of automation processes on a global basis. A COVID-19 caused downturn will likely go-ahead to a spike in automation; it means companies will reorganize their operations depending more on automated machine systems.
Whether it is in the processing or the packaging of the products, automating processes, and attempting to free the human hands are needed to advance industries. If there are two industries that we just cannot do without, it has to be the food and pharmaceutical industry. For food manufacturing companies enhancing productivity throughout their plants with the utilization of factory automation solutions is highly essential.
Also, the pharmaceutical industry is increasingly utilizing production automation and robotics to automate procedures in drug development, along with drug screening, anti-counterfeiting, and manufacturing activities. The solutions for pharmaceutical manufacturing companies can help attain suppleness, optimized production, as well as regulatory compliance through automation processes.
Enabling Industrial Automation
The enablement of automation is quite significant for diverse industries and sectors. Enabling industrial automation starts with automated washing, air-jet cleaning, sealing, capping, automated weighing, mix up prevention, automated printing & applying, labelling, pasting, coding, pick & place and tracking thousands of products with detailed reports through automation-based solutions.
Further, compromise in product quality, hygiene, and errors are enormous pains in all industrial sectors, be it Pharmaceutical, Food, FMCG, or Chemical Fertilizers. Human errors in packaging, labelling, or tracing can lead to hazardous consequences.
Coming to Industrial Quality Assurance solutions, they assist organizations in preventing mistakes, defects, and any kind of product issues. On the other side, Track & Trace Solutions make sure that every shipment is within the organization’s knowledge, every batch is tracked as well as traced, and the organization has the complete grasp of their products from anywhere across the globe.
Admittance and Penetration of Robots for Automation
Access and penetration of Robots don’t crop up at a balanced or a measured time and speed. As an alternative, automation occurs in burst out, especially in shocking times, such as economic disturbances, when humans turn comparatively more costly as the company’s revenues quickly decline. At these times, employers shed less-skilled staff and restore them with advanced technology and better-skilled workers, which boost labor productivity in a downturn scenario.
However, even new technologies will facilitate automation for manufacturers by enabling both humans as well as machines increasingly working side by side and adding up to more productivity.
Summary of Industrial Impacts that will accelerate the Rise of Automation Worldwide:
- Companies can rush to deploy automation technologies depending upon the impacts of Coronavirus on different industries.
- Automation may redirect the advancement of work and eventually retool most industries.
- Automation will help in speeding up workflows and enabling human contactless tasks.
- The use of automation will be increased to enhance the skill-sets of the current workforce.
- With industry automation, hygiene, accuracy, and speed of work can be better facilitated.
- Automation and robotics can lessen the labor costs as well as amplify work productivity.
Most enterprise companies have initiated and will find new ways of enabling their operational automation to boost productivity levels. One thing is sure that the impact of Coronavirus will positively change the definition of managing industrial operations across the globe.
Many economists have outlined these scenarios as the cyclical world of automation. So, if the future of work requires enablement of advanced automation, firm quality assurance, and smart Track & Trace Solutions, all these requirements need to be facilitated for addressing the Coronavirus pandemic signalling to the rise of automation.