Korea Filter Engineering will increase manufacturing 30% with Robotiq Lean Palletizing

Industrial producers usually wrestle with capability, labor pressure, and consistency.

At Korea Filter Engineering, guide palletizing of 10–20 kg (22-44 lb) industrial filter bins was limiting output, rising ergonomic danger, and slowing deliveries.

After deploying the Robotiq PE20 with a UR20, the corporate achieved:

• 30% manufacturing improve
• 50% discount in employee fatigue
• Close to 50% discount in injury-related absences
• Zero office incidents since set up
• ROI anticipated inside 2 years

This case examine reveals how collaborative robotic palletizing improves productiveness whereas defending staff in heavy-load manufacturing environments.

Firm overview: Industrial filter manufacturing in South Korea

Based in 1996 and based mostly in Gimpo, Korea Filter Engineering manufactures industrial filters utilized in electrical discharge machining (EDM).

• Trade: Industrial filter manufacturing
• Workers: 15
• Every day palletizing load (earlier than automation): ~4 tons
• Field weight: 10–20 kg

With a lean workforce and rising demand, guide palletizing grew to become a manufacturing bottleneck.

The problem: Guide palletizing of heavy bins

Earlier than automation, staff manually lifted and stacked roughly 4 tons of product per day.

Key points included:

1. Ergonomic danger and employee fatigue

• Repetitive lifting of 20 kg bins
• Again, shoulder, and muscle pressure
• Growing older workforce rising harm danger
• Fatigue affecting morale and consistency

2. Productiveness limitations

• Every day output capped at 200 bins
• Delays attributable to bodily pressure and absenteeism
• Issue sustaining constant throughput

3. Failed alternate options

Earlier lifting aids have been examined however operations repeatedly reverted to completely guide palletizing attributable to complexity or inefficiency.

The corporate wanted an answer that was:

• Compact
• Secure
• Straightforward to function
• Secure for human-robot collaboration
• Fast to deploy

The answer: Robotiq Lean Palletizing

In early 2025, Korea Filter Engineering chosen the Robotiq PE20 palletizer built-in with the UR20 collaborative robotic.

Why this palletizing system?

• Handles bins as much as 20 kg
• Helps as much as 20 SKUs
• Most pallet top: 2130 mm (84 in)
• Compact footprint for space-constrained amenities
• Works alongside workers with out intensive security fencing
• Intuitive interface requiring minimal coaching

Quick deployment timeline

• Early 2025: Analysis
• March 2025: Citation
• Could 2025: Set up and launch

Minimal format adjustments have been required. The system built-in seamlessly with the present conveyor.

Operators have been capable of be taught and run the system inside minutes, decreasing dependency on specialised robotics experience.

Outcomes: Measurable positive aspects in productiveness and security

1. 30% manufacturing improve

• Output elevated from 200 to 250 bins per day
• Larger throughput with out rising headcount
• Improved supply reliability

2. Improved employee well being and security

• Harm-related absences almost halved
• Employee fatigue decreased by greater than 50%
• Zero office incidents since set up

Younger-Hun Yoo, Assistant Supervisor in Manufacturing, shared:

“After utilizing the robotic, our our bodies are more healthy, and we really feel much less drained—lower than half in comparison with earlier than. We’ve extra vitality left for our households after work.”

3. Workforce optimization

• One full-time worker reassigned to higher-value duties
• Much less bodily pressure, extra operational focus
• Stronger group morale

4. Sturdy monetary case

• Anticipated return on funding inside 2 years
• Lowered oblique prices associated to harm and absenteeism
• Elevated capability with out increasing facility house

Why collaborative robotic palletizing works in heavy manufacturing

This venture demonstrates key benefits of cobot palletizing techniques:

Protects staff from repetitive heavy lifting

Eradicating 4 tons of each day guide lifting dramatically reduces ergonomic danger.

Will increase output with out increasing workforce

Automation dietary supplements labor as an alternative of changing it.

Scales with product variability

The PE20 handles as much as 20 SKUs, supporting various product strains.

Suits in space-constrained amenities

Compact design makes it viable for small and mid-sized producers.

Permits quick ROI

Measurable productiveness and security enhancements speed up payback.

Woo-Seok Kim, Director of Enterprise, defined the choice:

“We checked many robotic techniques, however the PE20 was probably the most secure. Defending our staff is an important factor, and the PE20 permits us to try this. That’s the reason it’s well worth the funding.”

Key takeaways for producers contemplating automation  

In case your operation includes:

• Guide palletizing of heavy bins 
• Repetitive lifting inflicting fatigue or accidents
• Labor shortages or growing old workforce challenges
• Restricted flooring house
• Productiveness plateaus attributable to bodily constraints

Collaborative palletizing automation could ship fast, measurable impression.

Korea Filter Engineering’s transformation proves that producers would not have to decide on between:

• Productiveness and security
• Development and workforce wellbeing
• Automation and operational stability

With the suitable palletizing answer, you’ll be able to obtain all three.

Is Lean Palletizing the suitable match to your manufacturing line? 

Use Robotiq’s Palletizing Match Instrument to shortly assess whether or not cobot palletizing is sensible to your operation and what a practical deployment might appear like to your facility. You will even get customized estimates for ROI and payback intervals and a 3D simulation of what Lean Palletizing might appear like in your manufacturing facility flooring.