FANUC SCARA robot on an SDC Flex Feeder

Custom Automated Tool Packaging Machine

Not One-Size-Fits-All: A Flexible Automated Packaging Solution

A leading international supplier in the cutting tool industry presented the need for a flexible automated packaging solution to add to their manufacturing facility. This machine needed to be able to package multiple sizes of drill tools. With this customer preferring integration of FANUC robots, it was a natural choice to partner with SDC, an authorized Level III FANUC robotic integrator, known for delivering precision robotic integration within automated packaging machines and automated manufacturing solutions.

Technical Components & Technologies

3 FANUC SCARA robots & FANUC 6-axis robot
Telesis pulsed-fiber laser
2 SDC Flex Feeders
Glideline power and free conveyor system with custom pallets
A-B Panelview 5000 HMI with Allen-Bradley PLC
Ignition software for connection between customer database and PLC
3 ATI end effectors with automatic robotic tooling changeover
Schunk electric gripper for precise positioning of gripper jaws to pick parts from pallets

The Machine Concept:

Each style needed its own packaging consisting of two different parts to encapsulate the tool. After the tool is packaged, label application needs to be performed before the part is vision-inspected and considered complete. This custom system was designed to enhance efficiency and precision in packaging.

This flexible automated manufacturing system was engineered to be robust, adaptable, and future-proof, offering scalable performance to meet evolving product demands. The system’s modular design and software programmability enable quick adjustments for new package styles, creating a truly scalable automation solution. The key challenges were as follows:

  • It’s not one size fits all – this machine needed to be flexible enough to handle the various parts and case sizes (20,000+ parts, 40+ different package types).
  • Designed with the future in mind – with consumer demand variability and continual product updates comes a greater need for manufacturing flexibility. Machine software and automated equipment needed to be easily adjusted to accommodate product changes.

Integrated key technologies for automated manufacturing solutions on a drill tool packaging machine

Solution:

To meet the demands of a high-mix, high-precision production environment, our team engineered a robust and flexible automated manufacturing system built on proven technology and deep industry expertise. Our team leveraged deep industry expertise in automated manufacturing solutions and automated packaging machines, to develop a scalable, intelligent solution that is as adaptable as it is reliable. The system integrates advanced robotics, vision systems, and custom tooling to deliver precision, repeatability, and efficiency at every stage of the process. Integrated key technologies included:

  • Precision Robotic Integration: Three FANUC SCARA robots are positioned around an SDC Indexing Ring. Two of these robots are programmed to work with SDC’s Flex Feeding system by vision guided part selection from a conveyor and inserting it into a custom nest. Another performs the task of unloading the packaged part from the machine. A FANUC 6-axis robot picks rotary cutting tools from custom pallets.
  • SDC Flex Feeding: These systems provide intelligent, vision-guided part handling, ensuring optimized pickability even for complex geometries. This capability maximizes robotic uptime and reinforces the reliability of automated packaging machines in high-speed environments.
  • Dial Indexer: Cam-driven rotary indexing dial for streamlined machine operation throughout each station.
  • Custom Tooling: Precision centering tooling custom designed by our engineers to ensure alignment between the part being inserted and the package bottom.
  • Custom Part Feeding Pallets: Each pallet type has dimensional information stored in the PLC, with room for additional types. The customer can re-teach the system as needed to refine the positions, as the robot needs to be very precise when removing parts to avoid binding up and lifting the whole pallet. To ensure alignment, we utilized the Soft Float function on the FANUC robot to allow it to self-align with the pallets.
  • Advanced Ignition Software: Facilitates real-time data exchange between the PLC and the customer’s expansive product database of over 20,000 different tools, reinforcing the system’s flexibility and adaptability to future tool variations.
  • Laser Marking: Part marking is done by a Telesis laser with unique programmable pattern files for each size.
  • Machine Vision: Fanuc iRVision on the SDC Flex Feeding stations, Balluff magnetic position sensors, and Keyence LR-W color sensors for label placement verification.
  • Electric Servo Gripper: Schunk EGU Electric gripper was used to allow 6-axis robot to precisely position gripper fingers between tightly packed parts with clearances as low as 0.5mm, with no tooling changer required to handle diameters from 3mm up to 20mm

Results & Business Impact:

The implementation of SDC’s automated packaging machine resulted in significant measurable improvements. By integrating advanced technologies, we’ve created a system that offers:

  • Improvement in Production: 750 parts per hour with operational efficiency of 98.5%
  • Increase in Product Capacity: This new machine is capable of more precise placement of the product into the new style package bottom, saving the step of operators having to transfer tools individually and increasing their capacity. Before this machine was developed, our customer assembled these parts by hand.
  • Technological Improvements with Reduced Operator Intervention: The rotation of tools when transferring between dials allows them to run a different style of packaging which previously had to be hand-loaded.
  • Ignition Software and Future Scalability: Seamless integration into our customer’s existing catalog of over 20,000 product sizes and styles with user-friendly programmability for future product additions.

Operational Workflow:

SDC Flex Feeding:

  • High-speed delivery of accurately oriented parts to the machine. Two FANUC SCARA robots integrated around the rotary indexing dial place the components of the product packaging into the nest to encapsulate the drill tool.

Automated Laser Marking:

  • Each part is marked with dimensional information and/or lot number

Servo-driven Part Placement

  • Servo-driven part placement orients the laser-marked drill tool and places it in the nest.
  • Parts can be placed tip-down or tip-up in the package, depending on package type.
  • The machine software calculates ideal positions for picking from laser dial and placement in package based on part and package dimensions.

Label Application:

  • Product-related information printed on an adhesive label is applied to the product packaging.
  • Machine automatically moves the labeler vertically and horizontally to accommodate different package sizes based on the recipe – no manual changeover required.

SDC Standard Products: Eliminating Engineering Risk with Proven Solutions

3D rendering of the SDC Flex Feeder

SDC Flex Feeding

Our SDC Flex Feeding systems are engineered to deliver a continuous supply of pickable parts, eliminating robotic wait times and maximizing pick rates for unmatched efficiency. Designed to keep parts moving seamlessly through your production process, our systems ensure that robots operate at peak performance with minimal downtime, significantly improving overall productivity.

These systems are constructed with carefully selected components that gently process small to medium-sized parts, regardless of shape or size. Leveraging decades of expertise, we’ve created a proven system that handles a wide variety of parts, ensuring smooth and reliable part delivery for your applications.

Key Features:
  • Continuous and Uninterrupted Part Supply: The SDC Flex Feeder is designed to ensure a steady flow of pickable parts, maximizing robotic pick rates, and preventing downtime.
  • Handles Complex Part Shapes Using Vision Guidance: Some parts can be difficult to pick due to factors including geometries, size, and orientation. Integrated vision systems guide the robot to accurately pick parts.
  • Smart Conveyor Technology with Automated Part Re-orientation: The integrated SDC smart conveyor system strategically moves and reorients parts to optimize pickability. Automated repositioning ensures that parts are consistently presented in an ideal orientation for robotic picking, reducing errors and increasing efficiency
  • Seamless Robotic Integration and High-Speed Performance: Built to work with a variety of robotic systems, the SDC Flex Feeder supports high-speed pick-and-place applications. The system’s high-speed robotics, coupled with built-in accumulation and buffering, optimizes production flow for maximum throughput.

Conclusion:

This project exemplifies the value of a well-engineered, flexible automated packaging solution. By integrating industry-leading robotic systems, vision technology, and smart software, SDC delivered a next-generation automated packaging machine that meets the demands of both today’s and tomorrow’s manufacturing landscape.

Through our role as a trusted FANUC robotic integrator (FANUC ASI), we provided a scalable, reliable, and efficient automated manufacturing solution that transforms a once-manual process into a repeatable, high-throughput workflow. The result is a robust flexible automated manufacturing system capable of adapting to product variability, reducing labor, and future-proofing the customer’s operations.

FAQ’s (Frequently Asked Questions)

Q: What makes this packaging solution “flexible” compared to traditional automated packaging machines?

A: This solution is designed to handle over 20,000 product variations and more than 40 different packaging types without manual reconfiguration. It uses recipe-based software, intelligent vision systems, and adaptable robotic tooling to quickly adjust to new part sizes, shapes, and orientations—making it a truly flexible automated packaging solution for high-mix environments.

 

Q: How does SDC’s experience as a FANUC robotic integrator benefit this project?

A: As an authorized Level III FANUC robotic integrator, SDC brings deep expertise in configuring and programming FANUC robots for precise, repeatable tasks. This ensures seamless robotic performance across complex workflows, from part picking and placement to packaging, labeling, and laser marking—all with high efficiency and minimal downtime.

 

Q: Can this system be scaled or upgraded in the future?

A: Yes. This system is built using scalable automation solutions, including modular components, flexible software (Ignition), and re-teachable vision-guided robotics. This allows customers to adapt the system for future product changes or increased production demands without significant re-engineering.

 

Q: What types of technologies are integrated into the automated manufacturing system?

A: The system includes:

  • FANUC SCARA and 6-axis robots
  • SDC Flex Feeding systems
  • Custom tooling and part-feeding pallets
  • Telesis laser marking
  • Advanced machine vision (Fanuc iRVision, Keyence sensors)
  • Ignition software for database integration
  • Schunk electric servo gripper These components work together to form a high-performance, flexible automated manufacturing system.

 

Q: What kind of business impact can be expected from implementing this system?

A: Customers can expect:

  • 98.5% machine efficiency
  • 750 parts per hour throughput
  • Elimination of manual packaging tasks
  • Improved product consistency and labeling accuracy
  • Reduced operator involvement with quick changeovers
  • Overall, the system provides a major boost in productivity, traceability, and adaptability.

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