Project Summary and Challenge
A steel bar manufacturer, located in Ohio, required a modernized automated solution for tagging steel bar bundles ranging from 1.875” to 7” in diameter, with as many as 38 bars per bundle. The legacy process involved attaching a specialty label embedded with RFID, which required precise folding and secure application. Historically, forklift drivers had to leave their cabs to print, fold, and manually apply tags to each bundle. This time-consuming, manual approach not only slowed down production but often resulted in mislabeled bundles, leading to production delays and quality risks. To improve accuracy, reduce delays, and support higher throughput, the operations needed a fully automated robotic tagging system that could function within a compact footprint, due to limited room dimensions.
The Challenge
The existing manual tagging process was slow, inconsistent, and placed a heavy burden on operators. Variations in bundle size and shape, combined with the complexity of folding the labels properly, created multiple challenges that limited operations:
- Inconsistent Surfaces: Bundle variations required a search method to locate a planar area large enough to apply the roughly 3”x4” tag
- Manual, Time-Consuming Tagging: Forklift drivers had to pause work to manually print, fold, and apply labels.
- Label Accuracy Risks: Misapplied or mislabeled bundles led to costly rework and production delays
- Space Constraints: The robotic system had to fit in a 70”x90” enclosed room while still allowing safe operator access.
- Extended Reach Requirements: The robot needed to reach outside the enclosure to both locate and apply tags across bundles of varying sizes
The Solution
To address these challenges, Premier Automation engineered a compact robotic tagging cell designed to fold, apply and verify RFID-embedded labels consistently across varying bundle sizes. The system was built to maximize accuracy and reliability while fitting within the facility’s space constraints. Key elements included:
- Collaborative Robotics: A Fanuc CRX-10iA/L robot provided the extended reach required to search for suitable surfaces and apply tags across bundles of varying shapes and sizes.
- Custom End-of-Arm Tooling: Specialized tooling folded the label precisely along its designed sections, ensuring full adhesion and long-term durability.
- Integrated Printing System: A Zebra printer with custom spool loading and unwind rolls produced the specialty labels efficiently, reducing operator handling and downtime.
- Compact Cell Design: The robotic system was engineered to fit within a 70”x90” enclosure while maintaining space for operator access to load and service labels.
The Result
The robotic tagging system delivered measurable improvements in speed, accuracy, and operator efficiency:
- Faster Cycle Times: Automated folding and placement reduced tagging to a 30-second cycle, significantly accelerating end-of-line operations.
- Improved Accuracy: Tags were applied consistently using mill Level 2 data, reducing the risk of mislabeled bundles.
- Reliable Label Folding: Automated tooling ensured precise folding and adhesion of labels, improving durability and performance.
- Reduced Operator Burden: Forklift drivers no longer needed to leave their cabs for tagging, improving workflow and safety.
- Compact Reliability: Despite the tight footprint, the system provided robust, reliable automation that fit seamlessly within the facility’s layout.
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Driving the future of manufacturing through collaboration
Premier Automation is a proud member of the ARM (Advanced Robotics for Manufacturing) Institute. The ARM Institute aims to be the leading catalyst of robotics innovation and expertise and to accelerate growth in US-based manufacturing and the high-value careers that go arm in arm with this industry change. ARM is dedicated to creating the ecosystem that will drive innovation in robotics.
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