With the introduction of an automation solution including ABB robots, ABB's Measurement and Analysis Technology division has successfully completed the conversion of logistics operations at its measuring instruments plant in Ossuccio, Italy. The new solution takes over all loading and unloading activities in the warehouse, which were previously carried out manually. This has reduced the time required for assembly by 30 percent and increased the overall efficiency of logistics by 90 percent.

The aim: to improve logistics and the production process

The ABB plant in Ossuccio specializes in the production of pressure transmitters that enable industrial companies to measure, monitor and control the applied pressure force. Pressure measurement is fundamental for both safety and performance and plays an important role in digital transformation. The plant, located on Lake Como in Italy, exports 90 percent of its products. The recent modernization aimed to optimize logistics and increase operational efficiency.

"We wanted to optimize both the logistics at the Ossuccio site and the entire production process," emphasizes Mariafrancesca Madrigrano, plant manager at ABB Measurement and Analysis Technology. "To find a solution, we turned to our colleagues at ABB Robotics. The system they implemented has improved our processes and goes hand in hand with our plans for the future."

The solution: Two modular production cells

The solution consists of two ABB OmniVance FlexBuffer cells. These are connected by a conveyor belt and equipped with ABB robots to ensure fast order processing. FlexBuffer effectively combines tasks such as intermediate storage and sequencing, offering an advantage over conventional systems, according to the supplier. The variant of FlexBuffer for mixed items allows companies to store a variety of cartons of different sizes, all handled by the same robotic gripper. Because the shelves can also be moved flexibly, all cartons can be stored with minimal loss of space.

"What could be more natural than to demonstrate the performance of an ABB technology in an ABB plant," says Eduardo de Robbio, Segment and Portfolio Manager Consumer Industries at ABB Robotics. "The FlexBuffer cell comprises an ABB robot, gripper and advanced software. It makes an important contribution to increasing output and efficiency and takes account of constantly changing requirements and customer wishes. The implementation at ABB in Ossuccio underlines the modularity of FlexBuffer. It makes it possible to optimally provide the storage capacity required for production."

Flexible and efficient operation

According to the provider, FlexBuffer systems are quick and easy to configure, install and maintain using a software suite. The system also has digital interfaces to various areas in plant planning and the technical departments. "Real-time tracking enables efficient planning and processing. There are also diagnostic functions that provide valuable insights in the event of problems," says Eduardo de Robbio.

By integrating ABB robot technology into the production process, operating costs, particularly in logistics, have been significantly reduced. "By eliminating manual activities, we have managed to streamline the production flow and also reduce the time required for assembly by 30 percent," adds Stefano Pizzetti, Factory Operations Manager. "This is crucial, as one piece is processed every three minutes. The system significantly improves our efficiency and our processes."

Focus on continuous improvement

The introduction of the system was the key to continuous process optimization at the plant. "By implementing the robot-supported automation solution, we have set the course for further innovations that will help us to respond even better to specific customer requirements and ensure customer satisfaction," summarizes Mariafrancesca Madrigrano. "The investment underpins our commitment to continuous improvement and innovation."