Isycod enhances technician workflows and automates dual applications with cobot integration

Isycod

With a UR5e cobot, the integrator Isycod improves the working conditions of technicians and automates two distinct applications

In short

Isycod, a certified Universal Robots integrator in the Rhône-Alpes region, has deployed a UR cobot within the SME Repack-S , a designer and manufacturer of high-performance, custom-made sealing and guidance solutions. The objective: to automate repetitive tasks to allow production team members to focus on higher value-added tasks and continuous improvement.

Automating precision and repetitive tasks to empower skilled technicians

Repack-S is an SME specializing in the manufacture of seals and sealing systems used in many sectors, such as aeronautics, motor racing, and the food industry. The company, which is made up of high-level technicians, wanted to improve their daily lives by automating certain repetitive activities in their profession.

The application integration was carried out by Isycod at the Repack-S site, based in Cuisery. This company, founded in 1997, employs 38 people and produces more than 350,000 seals per year in small batches.

The robot integration originally involved a quality control station. The coordinate measuring machine was loaded by an operator, a task that required the inspector to stay in front of the machine for several days, for cycle times of 3 minutes. The robot integration was intended to fully automate this station and run it overnight.

During its site visit, Isycod identified a second task that could be managed in a complementary manner by the same cobot.

Isycod

Industry Metals and Machining

Country France

Number of employees 573

Cobot used UR5e

Main value drivers:

Flexibility of the cobot capable of performing several different tasks without changing the end effector
Simplicity and intuitiveness of programming
Fully autonomous operation, with the possibility of technicians taking over control
No adaptation of manufacturing and control processes required

Tasks solved by collaborative robots:

Measurement and quality inspection of finished products
Use of machining machines

Automation challenges solved:

Increased productivity
Operator freed from repetitive tasks with disappearance of latency times
Remote supervision of the cobot's night work
Transfer of skills to technicians
Flexibility and profitability of investment thanks to dual application
Small footprint in the workshop and adaptable to existing machines

How they did it

A flexible cobot setup for dual automation tasks

To meet Repack-S’s automation goals, Isycod deployed a UR5e collaborative robot mounted on a mobile platform, allowing it to serve two distinct workstations efficiently.

Night Shift: The cobot performs dimensional quality control on complex sealing joints, with a cycle time of 3 minutes.
Day Shift: It handles loading and unloading of a lathe for part machining, operating across two 8-hour shifts.

The cobot is equipped with:

A Robotiq gripper from the UR+ ecosystem, with interchangeable jaws tailored to each task.
A laser scanner for workspace safety.
A steel rod to manually open non-automated machine doors.

A standout feature of this solution is the cobot’s ability to switch between two end effectors using its arm’s rotation axis—enabling seamless transitions between tasks.

For each application, Isycod designed a custom magazine that supports 8 hours of autonomous operation, minimizing downtime and maximizing efficiency.

A cobot adapted for precision tasks

Repack-S works on very small series with short cycles, the cobot is programmed in advance to know the movements to be carried out for handling each product. The UR5e cobot was chosen because of its versatility, the precision of picking up the part and repeatability. Force sensors in the UR5e allow it to locate and recognize the products. It picks up the parts and always places them in the same place, without ever damaging them.

Technicians simply bring the cobot to the machines, load the magazine with parts in 5 minutes (each application has its own loading magazine) and start the operation.

They also have access to an HMI (human-machine interface) to monitor the cobot, check that the operation is running smoothly and intervene in the event of a problem.

Operations carried out completely autonomously

Although the cobot operates completely autonomously, it is not unsupervised. A camera allows for real-time monitoring of what's happening. Technicians can connect directly to the cobot via their smartphone and remotely restart it if it stops working. Even at night, the robot informs technicians of any downtime or problems. For example, after 5 or 10 non-compliant parts, an alarm is triggered.

Boosted productivity and empowered technicians

The UR5e cobot, installed by Isycod in just 1.5 months, exceeded expectations at Repack-S. By automating two key workstations, the company achieved a 25% increase in productivity, without any job losses.

Technicians, trained by Isycod, now manage the cobot’s programming and maintenance independently. With repetitive tasks offloaded, they can focus on continuous improvement initiatives and bring greater value to their roles.

Thanks to the cobot’s high precision and repeatability, both stations now run autonomously, freeing up skilled workers for strategic projects. The installation included everything from supply and development to commissioning, all completed in record time.

A tailor-made project that has enabled us to optimize production while placing people in a high value-added role.

Charles Pelagali, General Manager ISYCOD

After picking up a seal, the cobot places it on the operating platform so that the measuring machines can begin its activity

The machine measures the seal and starts the quality control operation. The cobot turns the object over so that each side can be examined.

After the machine completes the quality control, the cobot places the seal in a box of scrap or validated products, and starts the operation again.

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