Manufacturing Quality and Efficiency Through Advanced Automation
For manufacturers, the question is no longer whether to automate, but how automation can help your company be more competitive. At Blue Ridge Industries (BRI), we have seen firsthand how molding automation transforms production into a streamlined, high-output engine of growth – helping to drive scrap reduction, faster cycle times, and the ability to maintain 24/7 production schedules without sacrificing precision.
Benefits of Automation
The primary driver for plastic injection molding automation is the pursuit of a more predictable and efficient production floor. When you remove the variable of human intervention, you gain a level of consistency that is impossible to achieve manually. This consistency is demonstrated in several ways that directly impacts an organization’s ROI.
First, automation allows for “lights-out” manufacturing. This means your facility can either increase production without increasing direct labor or maintain production with less direct labor. Additionally, robots and cobots do not experience fatigue, suffer from illness, or take time off. Whether it is cycle 1 or 10,000 of the day, a robotic arm will perform the same motion with the same precision, leading to a significant reduction in part damage and handling errors, as well as increase finished good consistency.
Automation Driving Efficiency and Quality
In injection molding, efficiency is measured in seconds and grams, so using injection molding automation helps ensure that every cycle is identical, stabilizing the thermal profile of the mold. Even small variations in how long a mold remains open can cause temperature fluctuations that can lead to warped parts or surface defects.
By using automated part removal, the press remains open for the same amount of time for every cycle, providing stability that leads to higher quality yields and a significant reduction in scrap rates. In addition, integrating vision systems allows for real-time quality control because the cameras can inspect parts for dimensional accuracy or short shots faster and more accurately than a human inspector. This ensures only 100% conforming parts make it into the shipping box.
Levels of Automation
Not every project requires a fully autonomous robotic cell. Understanding the different levels of automation is key to maximizing your operation without overinvesting in unnecessary technology.
Level 1: Basic Part Removal. This often involves simple three-axis Cartesian robots that pick parts and place them on a conveyor, reducing the risk of parts being damaged or contaminated by dropping into a bin.
Level 2: Integrated Secondary Operations. At this level, automation handles tasks such as automated gate cutting, automated bagging, and/or check weighing parts to ensure consistency and accurate part counts.
Level 3: Full Cell Integration. This is a comprehensive approach where cobots and/or robotics in injection molding manage everything from insert loading and overmolding to final assembly, packaging, and palletizing.
In-house Development
One of the most effective ways to ensure a high ROI is through in-house automation development. When a molder designs their own automation solutions, the technology is specifically built for the unique challenges of the parts being produced, and the in-house automation team can quicky resolve issues because they have an integral understanding of the automations systems.
At BRI, our team focuses on developing customized robotic systems that are specifically engineered for each injection molding project. By designing these interfaces in-house, we can optimize the interaction between the automation and the molding machine. This custom approach ensures the automation is not just a generic add-on, but a specialized tool designed to minimize cycle time and protect the integrity of the plastic components.
Types of Automation
The versatility of modern robotics allows us to target specific pain points in the manufacturing process. Depending on the complexity of your part, different types of systems may be employed:
Cartesian Robots: Ideal for high-speed pick-and-place and simple stacking. Over 90% of BRI’s injection molding machines are equipped with these robots.
Six-axis Robots: These provide the flexibility needed for complex movements, such as articulating a part for a specific automated gate cutting path or placing inserts into a mold.
Collaborative Robots (Cobots): Designed to work safely alongside humans, BRI’s three cobots are used for inspection tasks and packaging at the end of the line.
Integrating Automation
Successful integration is a marathon, not a sprint. To realize true ROI, the transition must be handled with a clear roadmap, beginning with a process audit to identify which machines or part runs are the best candidates for molding automation. High-volume, long-running programs offer the fastest payback period.
Next, the facility must ensure that the infrastructure (e.g., floor space, safety guarding, power requirements) is ready for the new equipment. Finally, training is essential. While the robots do the “heavy lifting,” your team must be empowered and educated to program, maintain, and troubleshoot these systems to prevent unplanned downtime.
By viewing automation as a long-term strategic asset rather than a one-time expense, manufacturers can secure a competitive edge that remains resilient even as market demands shift. The BRI team is committed to helping our partners navigate these technological advancements to achieve the best possible results for their plastic components.
Authored by Adam Noble, vice president, Blue Ridge Industries - Adam leads a cross-functional operations team in at BRI and sets the company vision and goals to guide the organization toward its 2030 Vision. He uses data and automation to improve efficiency and works with his team to take new products from first customer contact through full production.
