日本自働精機 List of Products and Services

We would like to introduce a case where a food manufacturer producing powdered juice implemented a "small box packaging line for powdered juice." Previously, the company conducted packaging operations with more than 20 staff members, but the work efficiency was poor and productivity declined. Reducing the production cost per unit through automation was a challenge. Therefore, through on-site surveys and interviews, we identified the labor-intensive processes and the tact time for each process, and based on those results, we constructed the line. This allowed us to reduce the number of staff from over 20 to 4. 【Case Overview】 ■ Challenges - Reduce maintenance costs and improve maintainability after implementation - Concerns about maintenance on-site due to installation overseas ■ Proposal and Implementation Details - After the line installation, all equipment can be repaired and maintained in a single visit - Developed a system to monitor the operational status of the equipment and the condition of driving components from within Japan *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where a customer manufacturing filter components expressed a desire to automate the packing and packaging process. The company faced the challenge of implementing a line that could achieve maximum labor savings within a limited budget for investment. To stay within budget, we proposed a specification where filter components and accessories would be manually fed. Since filter components and accessories are diverse, automating them would significantly increase initial costs. Therefore, we decided to automate the feeding of plugs, which can be automated and have a high risk of being forgotten. 【Case Overview】 ■ Challenge - Avoiding the risk of shipping defective products due to human error. ■ Proposal/Implementation Details - A specification that allows for automatic rejection of defects during transport to the stocker. ■ Effect - By avoiding the risk of shipping defective products, the number of complaints arising from the production process has also been reduced. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case in which we received an inquiry from a customer manufacturing drive components regarding the automation of their drive component packaging line. The company faced the challenge of wanting to introduce a single machine capable of packaging a variety of products due to the large number of product sizes, while also considering production volume and space constraints. To address this, we implemented measures such as making the box supply guide adjustable to prevent box misalignment during supply, thereby achieving automation with a single cartoner. 【Case Overview】 ■Challenges - They wanted to improve productivity by reducing changeover time. - They had a limited budget and wanted to minimize initial costs as much as possible. ■Proposal and Implementation - By using all-servo technology, we minimized the changeover time, including setup time. - We also reviewed the internal design of the equipment, reducing the number of parts to create a simpler structure. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry regarding the automation of the packaging line from a customer manufacturing steamed buns. The company faced a challenge as the packaging shape of their product was very unique, requiring a special molding of a single sheet of paper, and there were no general-purpose or standard machines that could accommodate this. In response, we developed a special insertion device that enabled continuous packaging of the uniquely shaped packaging. 【Case Overview】 ■Challenges - The production capacity was limited to 10 cases per minute per operator. - To supply to food factories, it was necessary to reduce the risks associated with the equipment. ■Proposal and Implementation - We achieved the automation of work for 11 operators by enabling packaging at a rate of 110 cartons per minute. - By designing all equipment with stainless steel and resin, we minimized the risk of foreign material contamination. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case in which we received an inquiry regarding the packaging and boxing line from a customer who manufactures eye drops. The company faced a challenge where, if they adopted a shuttle method for the product supply in the boxing process, they would not be able to meet the cycle time. In response, we proposed and delivered a ceiling transport rotary system. By allowing hangers to circulate, it became possible to reduce the return time that occurs with the shuttle method. 【Case Overview】 ■Challenges - There are multiple accumulation specifications, but we want to maximize compatibility and keep the introduction costs low. - We want to automatically insert not only eye drops but also dividers, notification cards, package inserts, and light-shielding cases. ■Proposal and Implementation - By switching the supply ON and OFF during setup changes, we achieved production with common equipment. - We designed and manufactured various dedicated equipment for standard cartoners and added them as options. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing cosmetics regarding the semi-automation of their packaging line. The company faced concerns that due to the short and elongated shape of the carton, if formed using a sliding method, the boxes would warp, leading to a high number of defective products. To address this, we proposed and installed an air suction-type lifting device instead of a sliding-type device, thereby reducing the risk of box warping as much as possible. 【Case Overview】 ■Challenges - They wanted to improve productivity by transitioning from a fully manual process to a semi-automated process. - The process involved many steps, such as mold adjustments, during changeovers. ■Proposal and Implementation - By establishing two areas for product input, we addressed the improvement of cycle time. - We proposed and installed a unit that allows for one-touch changeovers, achieving stable operation. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing powdered soup regarding the increase in production capacity of their existing equipment. The company faced challenges due to the low shape of the boxes, which could lead to deformation such as bending if the cardboard forming specification was set to a sliding method with claws. In response, we selected and proposed a box forming method using a vertical suction system with a servo motor. By implementing this in two processes, we were able to meet the customer's production capacity. 【Case Overview】 ■Challenges - The mechanism at the transfer section interfered with the equipment of the previous process when using a floor-based mechanism. - We wanted to prevent the mixing of defective products overall by minimizing the misdelivery of defective products to the subsequent process as much as possible. ■Proposal and Implementation - We proposed a circulation-type intake device at the top, achieving a smooth transfer section. - We installed a defective product discharge device to prevent the misdelivery of defective products to the subsequent process without stopping the line. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer handling pharmaceuticals regarding the automation of a small box packaging line. The company faced the challenge of wanting to improve productivity by enhancing maintainability within a limited space and minimizing production downtime as much as possible. In response, we proposed and installed a specification that allows for the manual movement of the hopper, enabling movement and maintenance even when boxes are set. 【Case Overview】 ■Challenges - To realize a small box line with a consolidated system - To enable box forming from either direction ■Proposed and Implemented Solutions - Achieved a consolidated system by installing an accumulation device during the transport to the packing process - Made it possible to form boxes from either side simply by changing the installation method *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing plastic ampoules regarding the automation of their packaging line. The company faced the challenge of wanting to achieve stable production not only to secure production capacity through automation but also to reduce the NG (non-conformance) rate caused by human error. By proposing and delivering a custom cartoner that achieves a maximum capacity of 165 units per minute, we enabled automation that allows for stable production. 【Case Overview】 ■Challenges - The quality guidelines are high, and they want to keep the NG rate low when sending products to the next process. - They want to prevent issues such as wavering and establish a stable automation line specification. ■Proposal and Implementation - By installing document inspection at each process, we significantly reduced the NG rate in the subsequent processes. - We used slippery guides to correct positioning. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer dealing with automotive parts regarding the automation of their assembly and packaging line. The company faced the challenge of wanting to implement a small box line that could handle a wide variety of supplies and setups in a single piece of equipment. To address this, we divided the parts feeders into two groups and used a dedicated machine for cap installation, achieving upstream automation. Additionally, by installing a switching device in the middle of the transport process, we enabled production on the same line. 【Case Overview】 ■Challenges - There were many specifications for the equipment within the factory, and we wanted to realize equipment that could accommodate these. - The budget was limited, and we aimed to minimize initial costs while achieving automation. ■Proposal and Implementation - Selection and delivery of equipment that met the particularly challenging height restriction of FL +1500mm. - Signal lamps indicating the operational status of the equipment can be checked from any position. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received a request for automation of the packing and packaging line from a customer manufacturing pharmaceuticals. The company faced challenges due to the variety of product and box specifications, as well as the desire to maximize compatibility for products with small lot sizes and different packaging forms. To address this, we implemented a unified line by branching and merging manual processes and automated processes based on the number of product lots. 【Case Overview】 ■Challenges - We want to outsource to a manufacturer that can handle everything from product input to boxing, packaging, and transportation consistently. - We want to implement measures to minimize the risk of production stoppage during work interruptions or malfunctions. ■Proposal and Implementation Details - By designing and manufacturing various equipment in-house, we reduced the customer's workload. - We proposed and installed buffer equipment to minimize production downtime in the event of a malfunction. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing pellet gum regarding the automation of their pellet gum packaging line. The company needed to accumulate and package blister packs of pellet gum at a capacity of 300 sheets per minute in a configuration of 2 rows and 5 layers. To achieve this, we designed a system that distributes the blister packs, which are conveyed at high speed from the PTP machine, to two accumulation devices, each with a capacity of 150 sheets per minute, thereby ensuring stable equipment operation. [Case Overview] ■ Challenges - To extract and accumulate 300 sheets while minimizing defects and reducing the defect rate. - To shorten the time required for changeovers, as the entire production would stop during this process. ■ Proposal and Implementation - Installed a weight checker and discharge section for inspecting defective products to prevent downstream transport of non-conforming items. - Achieved 24-hour production by operating with two machines each. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing batteries regarding the automation of a line for packing shrink-wrapped batteries into boxes. The company wanted to improve productivity through automation, but faced the challenge of limited budget, needing to reduce initial costs to achieve automation. As a solution, we focused solely on weight inspection, excluding the appearance inspection process conducted in the later stages, and implemented a roller-type stamping method to reduce costs. 【Case Overview】 ■Challenges - Desire to minimize the installation layout - Aim to avoid long production stoppages by simplifying the mechanism and shortening recovery time ■Proposal and Implementation - Achieved space-saving by standardizing the product input and part of the cardboard forming process - Reduced the number of parts to enable quick production recovery through simple part replacement in case of trouble *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing contact lens cleaning solution regarding the introduction of a packaging line. The company faced the challenge of improving production efficiency by automating the process to change the orientation of the cleaning solution during the input stage, allowing for both transportation and orientation change in a single process. To address this, we installed a parallel robot in the available space above the conveyor, enabling the orientation to be changed during the process of picking up from the belt conveyor and setting onto the bucket conveyor, thus allowing for transportation and orientation change in one step. 【Case Overview】 ■ Challenges - There are types for one, two, and three bottles, with the one-bottle type having a maximum specification of 105 CPM. - The box forming also requires very high capability, aiming for stable operation while minimizing defects. ■ Proposal and Implementation - The high-capacity one-bottle type is equipped with a dedicated continuous box filling device, while the two-bottle and three-bottle types utilize a top and bottom suction type box forming, achieving a capacity of 105 CPM. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry regarding the automation of the packing and packaging line from a customer who manufactures medical testing reagents. The company had been producing manually until now but faced the challenge of wanting to improve productivity through automation. As a result, human intervention is limited to the work set and the collection process of empty buckets, while automation has been achieved in other processes. 【Case Overview】 ■Challenges - Although it is an automation of a continuous line, the available space is limited. - We want to ensure that on-site workers can easily restore operations in case of misalignment or damage. ■Proposal and Implementation - Developed and delivered a new wrap-around case packer with a width of approximately 600mm. - Manufactured and delivered adjustment jigs for auxiliary units that may require adjustments. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing medical tape regarding the automation of their medical tape packaging and boxing line. The company faced challenges with the unstable operation of existing machines, leading to transport and packaging defects, as well as time-consuming setup changes. To address this, we inherited the specifications for the magazine installation from the existing machines and significantly reduced setup time by changing the specifications for the subsequent processes (such as adjusting both side guides to a single side guide adjustment). [Case Overview] ■ Challenges - Maximum packaging capacity of 20 boxes per minute (20 sheets per box) - Need to accumulate and package medical tape at a capacity of 400 sheets per minute ■ Proposal and Implementation - A specification to quickly extract medical tape from the magazine and count it using a photoelectric sensor - Optimized specifications to avoid double feeding due to static electricity and ensure no accumulation defects *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing coffee regarding the automation of small box packaging on their instant beverage production line. In the existing machines of the company, the dual-purpose design contributed to a significant number of defects in box forming and product insertion. In response, we designed and developed a special cartoner that can handle both standard square boxes and special boxes. This helped avoid forming and insertion defects, improving yield, and also achieved increased productivity through enhanced capacity. 【Case Overview】 ■Challenges - Minimize the defect occurrence rate to improve yield and productivity. - Shorten the changeover time between square boxes and special boxes compared to existing machines to enhance operational efficiency. ■Proposal and Implementation - By using a continuous machine, we avoided forming and insertion defects, achieving improved productivity. - Eliminated the need to change the box forming unit and forming guides during the changeover between square boxes and special boxes. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case of replacing a special box automatic packaging and boxing machine that was delivered to a customer manufacturing trout sushi. In the previous setup, only the packaging and boxing processes were automated, while the supply process was handled manually, presenting a challenge to automate the supply process. Therefore, we proposed a system where an arm controlled by a robot cylinder picks up three workpieces from the conveyor after the banding process and transports them to the supply conveyor of the packaging and boxing machine. After implementation, adjustments such as synchronization were made to achieve stable operation. 【Case Overview】 ■Challenges - The allowable downtime for operation is overnight from evening to the next morning, during which the removal and installation of the equipment must be completed. ■Proposal and Implementation Details - By assembling units that can be pre-assembled before delivery, we shortened the work time. - To ensure that adjustment work does not take much time on-site, thorough adjustments were made before shipment. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received an inquiry from a customer manufacturing liquid foods regarding the automation of their product packaging line. The company faced a challenge where using a robot that fits within the layout could not meet the required takt time of 60 boxes per minute. As a solution, we proposed and implemented an overhead circulating transport system that integrated conveying and product insertion into a single piece of equipment, successfully fitting it into an effective layout. [Case Overview] ■ Challenges - During insertion into boxes, collisions occurred with the conveyor at the bottom of the boxes, leading to workpiece damage. - Misalignment during box assembly caused assembly defects, and interference between the box sides and products during insertion caused the products to float. ■ Proposal and Implementation - Changed the material of the rollers to rubber rollers to absorb impact during insertion, preventing damage. - Installed correction guides on the conveying conveyor for the bottom flap assembly and the insertion points on the top surface to ensure proper positioning. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received a request for an automatic packaging and boxing line from a customer manufacturing eye drops. The company faced the challenge of reducing outsourcing management workload by entrusting the entire process from product input to packaging, boxing, and palletizing to a manufacturer capable of handling it all. To address this, we reduced the customer's management workload by constructing the line with our company as the point of contact while utilizing some equipment from other companies. 【Case Overview】 ■ Challenges - The introduction of a new line is required, but factory expansion is not possible. - Maximize automation of setup changes to improve productivity. ■ Proposal and Implementation - Constructed the line to be delivered without factory expansion. - Managed all processes with a single main control panel. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case in which we received an inquiry regarding packaging and boxing lines from a customer who manufactures eye drops. Initially, the company requested automation for packaging and boxing lines for only 10-bottle and 50-bottle packs, but they faced the challenge of improving productivity by also automating the packaging and boxing for 1-bottle and 5-bottle packs. To address this, we constructed two lines: A/ a combined line for 1-bottle and 5-bottle packs, and B/ a combined line for 10-bottle and 50-bottle packs. Both lines are designed to be interchangeable up to the accumulation process, after which they are laid out to branch off. 【Case Overview】 ■Challenges - There are four types of boxes for 1-bottle, 5-bottle, 10-bottle, and 50-bottle packs, but the goal is to maximize compatibility while keeping the introduction costs low. ■Proposal and Implementation - In addition to allowing compatibility up to the accumulation process, we have also designed the cardboard case and labeler used for box printing to be interchangeable, thereby reducing the introduction costs. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case in which we received an inquiry from a customer manufacturing sausages regarding the introduction of a new packing and packaging line. In this company, sausages are packaged in sets of four, and it is necessary to box them together. However, due to the characteristics of the sausages, aligning and accumulating them is difficult. They requested a solution to this challenge to achieve labor savings. We proposed a system where sausages are manually fed onto a conveyor at arbitrary timings, transported to a horizontal conveyor, accumulated on the horizontal conveyor, and then collected into sets of four using a star wheel, thereby achieving stable operation. 【Case Overview】 ■Challenges - There were limitations on the effective space available for constructing an automated line in the area where the existing line was installed. By installing a new line in that space, we aimed to improve space productivity. ■Proposal and Implementation Details - Since it was necessary to construct a new line in the existing line's installation space, we designed the supply line to the cartoner in an L-shape to fit within the effective space. *For more details, please refer to the related links or feel free to contact us.

We would like to introduce a case where we received inquiries about packaging and boxing lines from a customer manufacturing medical testing supplies (four-sided seals). The company faces the challenge of improving productivity by introducing a boxing and packaging line that can increase yield without defects, despite the difficulty of inserting products and accompanying documents into small boxes that are only 11mm high. During tests conducted by other companies, the thinness of the boxes affected the insertion of products, leading to rejections, which was a major concern for the customer. However, by optimizing the specifications for box insertion, banding, and accumulation and transportation, we have achieved stable boxing. [Case Overview] ■ Challenges - The box size will change, but by adopting a dual-purpose specification, we can keep the introduction costs down. - Build a line that can reliably discharge defective products, ensuring brand value. ■ Proposal and Implementation - Packaging and boxing that minimizes defects to the greatest extent possible has been made possible. - Inspection machines have been installed at each stage to address issues such as weight checks and box type inspections using barcodes. *For more details, please refer to the related links or feel free to contact us.