Masinara, a leading Bologna-based manufacturer of door and window frames and shutters, has implemented an advanced automation solution for the management of palletisation and depalletisation operations. At its facility, a robotic cell managed by ABB robots and Modula automated warehouses operate in a synchronised fashion to optimise the production flow.
The metal bins typical of the sheet metal stamping and assembly production sector have been replaced by seven Modula ML50D automatic warehouses, with a dual external bay. These were subsequently integrated with an ABB robot, which moves between the two Modula rows on a 16-metre ABB TRACK Motion IRBT linear guide.
Complete Automation in Door, Window and Roller Shutter Management: The Case of Masinara
The dual bay warehouses, which previously required human intervention, are now managed entirely automatically by the anthropomorphic robot. The project was carried out in collaboration between Modula and ABB, and involved in-depth software coordination, with the integration of ABB’s Deck software and the Modula WMS.
Automated Processes Managed by ABB and Modula
- Depalletisation: The product arrives from production on pallets, and is placed in the automated cell. The robot picks up the pallet, identifies it by barcode, and weighs the package for quality control. Afterwards, the product is transferred into the Modula trays according to a preset pattern.
- Palletisation: In order to execute a picking order, the WMS displays the customer’s order and creates the picking missions. These are then confirmed by the DECK software, which organises them based on the palletising plan. After receiving the mission, the robot picks the necessary packs from the Modula trays. Equipped with an artificial viewing system, the robot’s prehensile gripper guarantees precision picking operations.
Masinara is an excellent example of the successful implementation of an automated island, which offers significant advantages in terms of safety and ergonomics. The operators are relieved of having to handle heavy packages or work in confined and dangerous spaces. In addition, the automation has optimised the picking times, as the Modula warehouses are loaded during the evenings, when the operators aren’t present.