About the company
The project was carried out for the AFFI Group, a socially responsible company recognized for its expertise in industrial subcontracting and logistics outsourcing. AFFI offers a wide range of services covering the packaging, assembly, warehousing, and distribution of various products.
Thanks to its essential role in the manufacturing sector, the company supports numerous organizations daily by offering flexible, reliable operations tailored to their needs. This rich and complex operational context served as the starting point for the implementation of our automated solution.
Our mandate
Before our intervention, AFFI’s two production lines relied entirely on a manual process for box formation. This method required constant attention from employees, who had to continuously monitor the operations, which sometimes slowed production. AFFI’s main objective was to streamline box assembly while reducing the operational pressure on their teams.
Our mandate was therefore to fully automate the box formation process in order to free up three to four employees, who could then be reassigned to higher value-added tasks. In addition to improving productivity, this automation aimed to reduce non-conformities, optimize workplace ergonomics, and implement a more stable, sustainable, and efficient process.
Project implementation
First step completed
Factory manufacturing and testing: The first step took place in our laboratories. We designed and manufactured the box forming unit, then conducted comprehensive testing with the four formats used by the customer. This phase included mechanical and electrical design, programming of the robot, the human-machine interface (HMI), and the programmable logic controller (PLC).
The equipment was then fully assembled and prepared for transport. The customer had been informed in advance of the installation requirements (floor space, pneumatic and electrical power supply, internet connection) to ensure a smooth commissioning.
Second step completed
Delivery and installation: Our team traveled to AFFI’s site for a full day. We carried out the pneumatic and electrical connections to the existing infrastructure, then proceeded with the final assembly of the BAS system.
Third step completed
Start-up and production launch: In the final stage, we validated the four box recipes, trained a key operator, and supported the AFFI team during the start-up. As soon as the training was complete, the client was able to take control of the machine’s operations and launched production independently.
The preferred solution
The integration of the BAS solution enabled AFFI to achieve tangible benefits within the first few weeks of operation. The company observed a significant improvement in production quality, a substantial reduction in downtime, and a decrease in non-conformities. Automation also contributed to improved ergonomics at the workstation, thereby reducing the risk of repetitive strain injuries.
In addition to optimizing overall line performance, the solution has enabled estimated annual savings of $100,000, while increasing the stability and efficiency of the box formation process.
Is the SAB solution suitable for your business?
You have questions:
- How long will it take to recoup this investment?
- Can the system adapt if my production changes?
- Can my current employees learn to use it easily?
- What happens in case of a breakdown?
We have answers.
