Mandom Co., Ltd., a manufacturer of cosmetics and fragrances, has automated its production processes by integrating Universal Robots (UR) into its operations. This initiative was driven by the need to address labor shortages and reduce reliance on outsourced production.
Facing high costs and limited versatility of traditional labor-saving equipment, Mandom sought a more adaptable solution. The company chose UR robots for their user-friendly programming and operational intuitiveness. This decision led to the establishment of an unmanned production line that reduces costs and enhances the company's ability to design and build production lines internally.
Naoki Sasagawa, General Manager of the Production Engineering Division, noted the challenges faced by the company, stating, "We believed that by using robots, we could eliminate dedicated parts and make changeovers easier, which is why we decided to move forward with automation." Mandom initially considered conventional industrial robots but found them unsuitable for their high-mix, low-volume production needs.
In October 2020, Mandom introduced the UR5e robot for the cap-tightening process, followed by the addition of six more robots over the next year. This implementation allowed for the automation of various processes, including inserting liners into bottles, tightening caps, transferring products, printing, inspecting, and palletizing.
The UR robots have effectively ensured precise operations, utilizing built-in force sensors to control torque during cap tightening, thereby preventing issues related to over-tightening or leaks. The integration of peripheral devices like feeders and turntables with the robots has streamlined the entire production process.
By designing and operating the production line in-house, Mandom has improved its internal technical capabilities and reduced the volume of outsourced production, which previously involved around 40,000 to 50,000 trial product bottles monthly. The company is now looking to expand the application of its automated line to a wider range of products and replicate the setup in its overseas facilities.
Founded in 1927, Mandom Co., Ltd. continues to evolve its manufacturing processes to meet modern production demands while enhancing efficiency and reducing costs through automation.
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