AMT Solves a Critical End-of-Line Challenge

Overcoming a Major Automation Roadblock with Innovation and Expertise

A complex automation project was struggling when a system integrator, after acquiring a smaller company specializing in end-of-line packaging, struggled to meet the production rate required by their end user. The project, plagued with delays and setbacks for nearly two years, faced an ultimatum from the end client: deliver results or risk losing business entirely. Enter AMT.

AMT identified the key challenges, implemented strategic solutions, and ultimately transformed the project into a success story that exceeded expectations.

The Client’s Challenge

AMT’s client was a system integrator known for excelling in primary line packaging—think high-speed production lines for food processing manufacturers, such as burger production. Their expertise, however, ended before the final stage: palletization. To bridge this gap, the integrator acquired a specialized end-of-line packaging company, inheriting an active project with a major food processing company.

However, the acquisition had an unintended consequence—there was a reorganization of the engineering team, leaving the new team to pick up where they left off. The end-user issued a stark warning: complete the project or face contract termination.

Initial Struggles and Missteps

For nearly two years, the integrator attempted to complete the project but struggled to meet expectations. The Factory Acceptance Test (FAT) was delayed multiple times due to persistent issues. The primary challenges included:

• Throughput Deficiencies: The system was only achieving 50% of the required production rate.
• Data Tracking Complexities: The end-user needed a system that could track products from start to finish, regardless of operator interference.
• Mismatched Equipment: A pre-built robotic system was implemented without fully understanding its limitations, creating software bottlenecks.

AMT Joins the Team

With millions of dollars at stake, the integrator contracted AMT to bolster the team. Given only four months to get the project back on track, AMT’s engineering team quickly assessed the situation.

Key Steps Taken by AMT:

1. System Analysis: AMT engineers conducted a thorough evaluation of the existing system, identifying gaps between requirements and performance.
2. Strategic Modifications: Instead of a full redesign, AMT made targeted improvements to optimize efficiency.
3. Custom Software Implementation: AMT introduced their proprietary Recipe Builder software for palletizing, replacing the inefficient pre-built robotic solution.
4. Reliable Data Tracking: AMT developed a robust tracking system to maintain product traceability, even if operators intervened.
5. Building Trust with the Integrator: AMT provided detailed technical justifications for each change, ensuring the integrator had confidence in their decisions.

The Results: A Major Turnaround

With AMT’s involvement, the project saw a remarkable transformation:

• Production rate exceeded requirements by 20%
• Successful FAT completion after nearly two years of delays
• Seamless collaboration between AMT’s service and systems engineering teams

Ben Kurth, Engineering Manager, reflected on the experience: “This was an incredible collaborative effort between the client and AMT’s engineering and service teams. The project was extremely challenging, but by leveraging our expertise, we were able to deliver a solution that not only met but exceeded expectations.”

Conclusion: Turning Obstacles into Opportunities

This case highlights the power of strategic problem-solving and collaboration. AMT’s ability to step in, diagnose the issues, and implement efficient solutions underscores their leadership in automation engineering.

For companies facing similar end-of-line challenges, AMT has proven that expertise, innovation, and teamwork can turn a struggling project into a resounding success.