Automation of the Manual Palletizing Process through Integration of a Manual Feeder into the Auto Palletizing Module

Abstract

This project was conducted at Medtronic, a medical device manufacturing company operating in a high-volume production environment. It focused on enhancing the palletizing process for a specific medical product by integrating a manual feeder with an existing automated palletizing module. The manual method previously used led to inefficiencies in cycle time, increased operator fatigue, and elevated risk of human error. The implemented solution aimed to reduce cycle time, improve throughput, and enhance operator ergonomics while supporting production scalability. The approach included a thorough analysis of the current workflow, validation of equipment, strategic integration, and post-implementation monitoring. Results demonstrated a reduction of 80% in palletizing time and error rates, alongside positive operator feedback regarding ergonomic improvements. The system's configuration allowed for a balance between automation and human input, reinforcing adaptability and operational flexibility. Ultimately, this automation initiative contributed to a more sustainable and efficient manufacturing process. Key Terms ⎯ Cycle Time Reduction, Ergonomics, Human-Machine Collaboration, Manufacturing.