Yuhan-Kimberly's Choice! Fully Automated Depalletizing and String Cutting 📦

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Yuhan-Kimberly's Choice! Fully Automated Depalletizing and String Cutting 📦

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예상 프로젝트 기간: 12주

적용분야: Industry > Textile·Paper, Application > Palletizing·Depalletizing, Sector > Manufacturing

Industry > Textile·PaperApplication > Palletizing·DepalletizingSector > Manufacturing

#yuhankimberly#depalletizing#stringcuttingautomation#yaskawa#marosol

Process Overview

This implementation case, implemented at Yuhan-Kimberly's Chungju factory, combines a Yaskawa industrial robot with a string cutting workstation to achieve automated depalletizing and string cutting. The client introduced the depalletizing system to reduce labor costs and work fatigue, and expressed strong interest in automating rope cutting and discharge to maximize cost savings and efficiency.

This solution sorts and cuts boxes of various sizes before feeding them to the case packer, improving the efficiency of the box feeding and rope cutting processes, while also reducing the physical burden on workers and ensuring safety.

Project Background and Objectives

At Yuhan-Kimberly's Chungju factory, the process of dismantling palletized boxes and loading them into case packers individually was entirely manual. This process was highly repetitive and presented a constant risk of safety accidents due to the use of knives during the removal of the twine.

The goal of this project was to automate the entire process, from depalletizing to loading into the case packer, minimizing human dependence. Furthermore, by unmanning the twine cutting process, we aimed to ensure worker safety, reduce fatigue and on-site personnel burden, and ensure stable plant operations.

구성요소

로봇	Yaskawa Industrial Robot GP50: This multi-joint robot, capable of high-speed, high-precision movements, is optimized for palletizing tasks. It can automatically load and return a variety of products, making it effective for industrial automation.
주변기기	Box Sorter and Rope Cutter: This workstation sorts boxes of various sizes, cuts the rope, and then discharges them. Safety Light Curtain and Fence: A visual barrier separates the operator and robot areas. If a worker approaches the depalletizing area, the robot immediately stops operating, ensuring safety.

작업순서

STEP 1.	Material Input: The worker supplies pallets with boxes stacked in them to the designated locations.
STEP 2.	Recipe input: After loading the specification information of the supplied box from the OP panel, operate the start operation button.
STEP 3.	Depalletizing: Based on the loaded recipe, the robot picks up the bundled boxes on the pallet and moves them to the sorting/cutting workstation.
STEP 4.	Box Sorting: The robot sorts the bundled boxes it has placed down using servo motors and air cylinders.
STEP 5.	Rope Cutting: Perform the rope cutting in an aligned state.
STEP 6.	Rope discharge: The cut rope is caught with a hook and discharged.
STEP 7.	Box Realignment: Realignment is performed to prevent the box from being misaligned during the rope cutting process.
STEP 8.	Box discharge: The robot feeds the cut boxes one by one to the case packer.

※ 마로솔 내의 모든 콘텐츠를 무단으로 복사 및 재창작할 경우 부정경쟁방지법 및 저작권법에 위반될 수 있음을 밝힙니다.

특장점

Special Features

Flexible handling for various box sizes: 27 different box sizes can be sorted and cut, regardless of size.
Free product loading conditions: Even if the number of bundled boxes on a pallet varies, the robot can perform depalletizing simply by entering the conditions on the OP panel.

Introduction Effects

Increased Efficiency: Automated depalletizing and cutting operations increase work speed and reduce operator fatigue.
Cost Savings: Process automation reduces labor costs and enables more efficient operations.
Improved Safety: Safety light curtains, safety mats, and laser scanners minimize the risk of accidents during operations.

도입효과

주요지표	The automated depalletizing and rope cutting solution introduced at Yuhan-Kimberly's Chungju factory has significantly improved work efficiency, safety, and workforce management. Previously, each process required two to three workers to manually disassemble boxes and remove rope. With the automated solution, only one worker is required to intermittently monitor the system, resulting in a workforce reduction of over 50%.
도입기업 피드백	The client commented, "The introduction of depalletizing robots not only reduced the physical burden on workers, but also significantly improved logistics efficiency. In particular, the well-equipped safety system created an environment where workers could focus on their work with greater peace of mind."

주요지표

The automated depalletizing and rope cutting solution introduced at Yuhan-Kimberly's Chungju factory has significantly improved work efficiency, safety, and workforce management. Previously, each process required two to three workers to manually disassemble boxes and remove rope. With the automated solution, only one worker is required to intermittently monitor the system, resulting in a workforce reduction of over 50%.

도입기업 피드백

The client commented, "The introduction of depalletizing robots not only reduced the physical burden on workers, but also significantly improved logistics efficiency. In particular, the well-equipped safety system created an environment where workers could focus on their work with greater peace of mind."

※ 마로솔 내의 모든 콘텐츠를 무단으로 복사 및 재창작할 경우 부정경쟁방지법 및 저작권법에 위반될 수 있음을 밝힙니다.

추천 도입사례

Automated automotive battery palletizing: Safely stack batteries weighing over 60kg with the YASKAWA GP225 💪

This solution automates the repalletizing process for Atlas batteries produced by Hankook & Company for export. Due to the diverse import pallet specifications, customer-specific palletizing patterns, and product types, the total number of possible scenarios exceeds 200. The goal is to standardize these scenarios and ensure line stability by supporting a throughput of 10 pallets per minute for medium-sized batteries and 6 pallets per minute for large-sized batteries. [Pallet Feeder & Pallet Conveyor] This solution allows for the use of up to five different pallet types per country, ensuring a smooth 10-stack logistics cycle. Destacked pallets are transported to the battery palletizing position and aligned simultaneously. Completed pallets are transported to the discharge position. [Battery Sorter] Batteries fed inline are automatically sorted into 1st, 2nd (series/parallel), and 3rd layers according to the preset palletizing pattern. The robot then discharges the batteries, repeating the initialization process. [Robot Palletizer] Once aligned, the batteries are picked and placed at the palletizing position on the conveyor, repeating the pick-and-place process according to the specified location and number of layers. Honeycomb feeds are automatically inserted into each layer according to the settings. [Honeycomb Feeder & Sorter] Automatically sorts and inserts honeycombs into each layer of NO-BOX batteries.

이미지 없음

Yuhan-Kimberly’s Choice: Fully Automated Depalletizing + Strap Cutting📦

Process Overview This deployment was implemented at Yuhan-Kimberly's Chungju Plant, delivering an integrated solution that combines a Yaskawa industrial robot with a strapping-cut workbench to automate depalletizing + strap cutting. The customer pursued a depalletizing system to reduce labor costs and operator fatigue, and showed strong interest in automating strap cutting and strap discharge to further maximize cost savings and operational efficiency. The solution handles mixed carton sizes by aligning (squaring) cartons, cutting and removing straps, and then feeding cartons into the case packer. This improves throughput and consistency in both carton infeed and strap removal, while reducing physical strain on operators and enhancing workplace safety. Project Background and Objectives At Yuhan-Kimberly's Chungju Plant, cartons arriving on pallets were previously broken down manually and then loaded one-by-one into the case packer. The work was highly repetitive, and manual strap removal using knives created a persistent risk of safety incidents. The objective of this project was to minimize reliance on manual labor by automating the entire process—from depalletizing through case packer infeed—and to achieve lights-out (unmanned) operation for strap cutting. This enables improved operator safety, reduced fatigue and staffing burden on the floor, and more stable, repeatable plant operations.