Smart Automation, Safer Workspaces: How One Manufacturer Doubled Production

For one industrial manufacturer, manual handling of lead material was more than just a cumbersome process—it was a safety concern. Operators faced prolonged exposure to a hazardous product, and inefficiencies in cycle time limited productivity. Determined to make a change, the heavy-duty parts maker partnered with Automation Solutions Inc. to engineer a custom solution that would not only increase output but also remove workers from direct contact with lead.

Automation Solutions Inc. approached the challenge with problem-solving expertise, crafting a system designed to streamline the workflow while prioritizing safety. The new automation process begins with operators working outside of the cell, loading lead plates and stacks into staging areas. FANUC’s high-speed, high-precision SCARA robot swiftly transfers lead plates to a turntable, indexing them for accessibility. From there, a FANUC M-710 Series press tending robot steps in—picking multiple lead stacks, lubricating the die to prevent sticking, and precisely placing new stacks for pressing.

With each cycle, completed stacks are automatically offloaded to an outfeed conveyor, dramatically reducing manual handling. The transformation has been profound. Where the customer once relied on labor-intensive processes to produce 1,200 units per day, the new automated system—with just one press running—has more than doubled output to 3,000 units daily.

But Automation Solutions Inc. system goes beyond production gains—it’s about rethinking operational constraints. Using 3D visualization technology ensures every solution is meticulously engineered before implementation, allowing customers to optimize floor space and fine-tune workflows before a single part is installed.

While the customer anticipated a month-long ramp-up to production, the system was fully operational within two weeks, achieving impressive productivity gains and creating a healthier workplace for employees.

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We solve problems. We overcome hurdles. And we help the customer maximize their ROI, increase safety and increase production.

Nick Miller Business Development – Automation Solutions Inc.