BTC Mold introduced four UR5 cobots into its plastic injection mold production lines to product moving, palletizing, picking and placing products for the inspection. With flexible cobot arms and easy programming, UR cobots are suitable for manufacturing processes where complex ergonomics are involved. These cobots saved over 35% of labor cost for BTC Mold, and solved a serious manpower shortage caused by work environmental issues like noise. They also significantly reduced the risk of occupational hazard in the factory.
The business transformation
Now 11% of BTC Mold’s manufacturing process is supported by UR cobots: greater agility has improved floor space utilization efficiency, and helped the company remain flexible on both operation and strategy. Therefore, BTC Mold can now immediately adapt its production lines to customers’ demand for high-mix, low-volume production, providing customized products of high quality and optimizing the company’s overall competitiveness.
A “full-process” manufacturer of plastic injection molds, BTC Mold has been committed to developing and optimizing plastic molding technologies for more than a decade, offering high-quality products to customers in Taiwan and abroad like FEC, SENOR, and renowned furniture retailers in Europe. By automating the production process, the company hopes to achieve its goals for more stable product quality and larger mass production in a more comprehensive manufacturing service for customers’ high-mix, low-volume orders.
BTC had introduced large-sized automated production equipment in its production lines. But these gigantic machines were noisy, bulky and risky, requiring large space for installation and safety distance. Other problems like recruitment and labor shortage also made it difficult for the company to achieve operation and strategy flexibility that would become necessary when output increased. Therefore, BTC Mold hoped to fill its labor gap by introducing flexible, low-risk cobots. With cobots’ ability to work in close proximity with humans, the company also wanted to reallocate human resources at production lines, optimize production efficiency and lower occupation hazard risks in a workplace that is friendlier and safer for employees.