Process Logic – Your Partner in Innovation
Process Logic – Your Partner in Innovation
Who we are
Founded on continuous innovation, Process Logic has been creating custom machinery and automation since 1988. We serve customers all over the United States and Mexico, and provide automation solutions that increase profits, improve product quality, and reduce or eliminate labor. Best known for thinking outside the box when it comes to our solutions, Process Logic creates machinery and automation outside the boundaries that other companies stick to. We’re able to come up with unheard of solutions by allowing our employees creative freedom and by fostering an innovative environment for them to thrive in.Solutions we offer
Unlike most companies, our innovation isn’t limited to just one industry. With satisfied customers in a variety of industries such as sheet metal, wood, plastics, appliances, printing, automotive, wine, proteins, construction, packaging, and more, we are continuously growing our areas of expertise. By working across multiple industries, we’re also able to take the unique approach of translating processes and ideas from one industry to another.In cases when custom machinery and automation isn’t needed, we also offer robotic arms. Capable of processes such as welding, packaging, assembly, and more, robotic arms can be an efficient alternative to human labor. Better yet, robotic arms can lift thousand pound items as if they were feathers with perfect precision and can move 180 parts a minute. Another solution in automation we specialize in is robotic carts. Useful for moving products around your factory, robotic carts can help to reduce or eliminate labor. Designed to work in tandem with employees, robotic carts can utilize obstacle avoidance technology. This technology enables robotic carts to sense if a human or object is in its way and is programmed to either wait for that obstacle to move out of the way before continuing or to choose a new route to its destination.
Problems we’ve solved
Printing case study
Problem to solve:
The company prints onto plastic parts that they sell to a retailer that sells online. The company is a US-based company that competes with a company based in Mexico. Being that there is a large pay scale difference, the US-based company loses market share and operates at low-profit margins. The company needs to find ways to significantly reduce labor costs to compete with the companies based in Mexico.
Process Logic’s solutions:
- Process one involves an employee picking loose plastic parts out of a box and loading them onto an indexing printing machine several thousand times in an eight-hour day. Process Logic created a machine that allows the employees to dump the parts into a hopper. Through several steps, Process Logic was able to orientate the part in the right direction. A mechanical arm can then place the part on an indexing table at the same rate as the indexing printing machine (100% labor savings).
- Process two is a continuation of process #1 above. The process was the part would come off the printer and would be loosely put into another box. The box is then brought to the packaging line, where a human takes the parts out of the box and has to orientate them correctly into the packaging machine. Process Logic showed the customer how by putting the two machines next to each other, they could take the parts that already have the correct orientation and place them into the packaging machine (100% labor savings).
- Process three involved one human taking a cubed shaped plastic part from a box and loading it into a printer. Next, that same person would load it onto a conveyor belt so the ink could dry. At the end of the conveyor, a human would take the part off and inspect the part for correct printing. If the printing was correct, it would be placed into a box. If the printing was incorrect, it would be put to the side to remove the printing. Process Logic showed the customer that we can implement two robotic arms. The first arm would take the part and load it into the printer, and then it would remove the part and show it to a vision system. If it passed, then it would be loaded onto the conveyor belt. If it failed, it would put the part off to the side to have the ink removed. The process also made it easier to remove wet ink compared to dry ink. The second robotic arm we placed at the end of the conveyor loading the parts into boxes (200% labor savings).
- Process four involves a human taking the square plastic parts out of the box, and then placing a label on the box, and then placing the part into a packaging machine. Process Logic showed the customer that a robotic arm could be used to remove plastic parts from the box, load it into the wrapper, and by modifying a labeling machine we could place the label inline (100% labor savings).
The numbers:ROI: 9 months
The number of positions no longer needed: 5
The cost per employee per year: $48,322
The cost of machinery: $177k
The savings or additional profit from automation per year: $242k
The current issue at hand
With manufacturing continuously and rapidly growing, companies are desperately searching for a solution to the current labor shortages. Not only are companies facing labor shortages, they are also still recovering from jobs lost during the pandemic and are trying to prepare for the Baby Boomer generation leaving the workforce.The solutions
Instead of continuing to throw money and effort into recruiting and training, many companies are starting to rethink their approach and are exploring the use of robotics and automation. While this may seem like a financially out-of-reach option, the opposite is actually true. With the popularity of the industry growing, costs have been dropping; making automation not only financially realistic but also financially beneficial. In fact, the ROI for robotics is less than a year in most cases and comes at a lower cost than human labor in all cases. In addition to being more cost effective compared to human labor, robotics also provide the benefit of unbeatable speed, strength, and precision. Even better yet, they’ll never need to take a sick day!Get in touch
www.processlogic.co(320) 654-8910
kurt.s@processlogic.co
