Trailblazing with Cobots: Kal Plastics's Revolutionary Shift

In a bold and innovative move, Los Angeles-based Kal Plastics has not only cut costs and risks but is now setting a global benchmark for efficiency and safety in the manufacturing industry. As pioneers in integrating the UR10e collaborative robot (cobot) into their trimming process, Kal Plastics has seen remarkable improvements, reducing trimming time by nearly half and decreasing late shipments to a mere one percent, all while enhancing employee safety.

Breaking New Ground in Thermoforming

Under the visionary leadership of Juliet Oehler Goff, Kal Plastics became the first known plastics thermoformer to utilize a cobot for trimming. “It was a risk, but a needed one,” Goff reflects, recounting her decision to diverge from traditional industrial robots and expensive CNC machines. Her innovative approach has resulted in setting new industry standards and providing a model for other businesses to follow.

Thermoforming involves shaping heated plastic sheets against molds, later trimmed to achieve final products. Typically, CNC routers have been the norm, but their significant costs and operational limitations prompted Goff to explore a more cost-effective solution. As stated in Tech Briefs, Goff’s decision to deploy cobots was informed by industry insights and a drive to maintain competitiveness without compromising on quality.

The Cobot Advantage: Efficiency and Flexibility

One major advantage of cobots over traditional machinery is their flexibility. With the installation of the cobot directly in the thermoforming cell, production has become significantly more streamlined. The cobot effectively manages complex trims, improving precision and consistency while eliminating the need for costly, dedicated floor space. This new efficiency has proven transformative for Kal Plastics, as Dan Sproles, a consultant, and director at SPE Thermoforming, attests. The cobot has successfully handled overflow work previously done by hand, putting a definitive end to disruptive overtime and ensuring timely deliveries.

Empowering the Workforce

Goff’s approach extends beyond technological adoption; it’s about empowering her workforce. By offering training in cobot programming, employees have transitioned from traditional operators to skilled technicians. José Luis, a seasoned operator, easily grasped cobot programming through accessible online resources, further illustrating how cobots can bridge the gap between manual labor and advanced automation seamlessly.

Initially, there was fear among staff about the technology replacing their jobs. However, Goff reassured her team with a focus on safety and skill enhancement. “I want you to rely on your knowledge and skills,” she stated, underscoring the cobot’s role as a tool for smarter, safer work.

A Vision for the Future

Kal Plastics’ adoption of cobots not only offers immediate production benefits but also sets the stage for broader applications across their operations. Goff envisions expanding the use of cobots beyond trimming, exploring other processes that can benefit from this technology. The ability to move cobots around the plant, thanks to their space-efficient design, underscores their flexibility compared to traditional CNC machines.

Kal Plastics stands as a testament to the potential of collaborative robotics to transform manufacturing. Their story serves as an inspiration to businesses worldwide that technology, when paired with vision and strategic foresight, can lead to unprecedented success.

Adopted and inspired by Universal Robots’ contributions to the manufacturing industry.