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Absolutely Spec-tacular!

LaborSave, the GOLD STANDARD of bag opening and emptying solution, is by no means standard when it comes to the level of electrical and robotic engineering, and the quality of craftsmanship.

With safety being a top priority, LaborSave is the only fully automatic sack emptying system approved by all major standard institutes, including CE, UL, TÜV, and GOST. The enclosed LaborSave systems are equipped with 10 different safety sensors, possibly making them the safest machines on any production floor.

Furthermore, LaborSave is built to operate under rigorous conditions, as is evident by its installation in factories worldwide where temperatures range from -20°C through 50°C.

The LaborSave factory is ISO 9001 certified, representing a commitment to the highest possible standards.

Want to learn how LaborSave can improve your plant’s operational standards?
call your local rep today.

Mission accomplished

An Italian subsidiary of the world’s largest provider of polyolefins uses multiple raw materials and wants to avoid material contamination in its material handling systems.

When ordering LaborSave, the company asked that no granules remained in the stainless steel #hopper of our automatic bag opening and emptying system. The requirement was addressed by LaborSave’s engineers, who added several components and adjusted the hopper’s gradients.

Once installed and commissioned it was clear the ‘no grains’ requirement was fully met by the LaborSave system. Only then the customer asked that no dust remain either.

After brainstorming ideas with the customer’s technical staff, LaborSave’s CTO came up with a Systematic Inventive Thinking (SIT) solution. Using LaborSave’s existing hardware and software resources, the customer achieved zero residue between uploading and handling one raw material to the next.

LaborSave. Creativity at its best.

Training seminar

Installation and commissioning of LaborSave, our fully automated debagging and emptying systems, always include a training session.

An installation we did in Thailand in late 2019 was no different.

Only this time operation staff members of neighboring factories were invited by the Thai customer to join the training session we held.

Before long, the companies who attended our seminar ordered the same LaborSave model they’ve seen during installation, including conveyors, stacker and raw material conveying and handling systems.

Covid-19 amplifies need for LaborSave

LaborSave’s sales skyrocketed shortly after Covid-19 hit the world. Want to know why?

Because many plant managers were quick to realize they needed to get creative when dealing with the virus’ adverse effects on the business’ financials and the compromised safety of their employees.

LaborSave successfully met their requirements on both accounts and then some.

With a capacity of up to 1300 bags per hour at more than 99.99% emptying rate, and in addition to its many other benefits, the fully automatic bag machine dramatically improves performance efficiency and the derivative cost structure and profit margins. It also ensures the safety of employees as it automates the labor intensive, close contact, task of manually opening and emptying raw material bags. And ... LaborSave is IoT-enabled, so emptying station information is displayed on any connected device.

The LaborSave production facility is already working at 150% capacity, so we have full confidence it can handle a few more orders …

Seeing is believing

Our 120 sqm booth at K-2019 featured a working LaborSave system in all its glory.

We had numerous appointments scheduled for the show. We also had many unscheduled walk-ins. Some of which ended up being cold sales to customers who were so impressed by what they saw, they simply had to seal the deal.

One of these random walk-ins was the CEO of a German extruded piping company, who used manual labor for opening and emptying their raw material bags. Excited by the LaborSave system at work, the CEO immediately invited the rest of his team to join him. It took an hour of demonstrating and explaining the LaborSave features, before the CEO decided he had to switch to fully automatic sack opening and emptying system. He scribbled the deal’s details on a piece of paper he tore from his notebook and transferred down payment on the spot.

The owner of a blown film factory from the Dominican Republic was another unplanned visitor. Impressed by the ingenious system and the huge cost savings opportunity on both labor and raw material waste, she used her napkin to write down and sign the deal. Down payment was transferred, yet again, the same day, as she wanted the system ASAP.

They say “A picture is worth a thousand words”. Seeing a LaborSave system at work is worth much more …

Semi-automatic. Semi-efficient.

Semi-automatic bag “slitters” and “blenders” are … semi-efficient, at most.

These expensive material handling solutions typically require manual feeding of raw material bags, pose high contamination risk, and have limited throughput and large and ever-increasing rate of raw material loss.

The fully automated LaborSave has set a new standard for bag opening and emptying, offering a best-in-class solution in all aspects imaginable.

Want to be an efficient operations leader, and enjoy fully-automated savings on raw materials, labor, storage and transportation? Contact an authorized sales rep in your country. Today.

 

Effective cost-saving technique

A vetted approach to tackling unanticipated expenses associated with events occurring on the production floor is benchmarking against past events.

Once a list of such direct and indirect expenses has been formed, it is time to use root cause analysis to determine the underlying reason for the occurrence of past events and derivative expenses. According to Wikipedia, root cause analysis is a method of problem solving that tries to identify the root causes of faults or problems. A root cause is a cause that once removed from the problem fault sequence, prevents the final undesirable event from recurring.

We’ll use a hypothetical case of employee injury to demonstrate the root cause analysis technique.

When investigating the injury, the company that employed the employee, determines that working a double shift was the reason for the employee’s exhaustion and resulting injury. Root cause analysis mandates that the company would then consider the question why the double shift was necessary in the first place. Reverse-checking the causes per step of the occurrence, the analysis could end with the conclusion that use of manuals for training new employees was required – see image for a detailed visualization of the hypothetical case analysis.

Use of the root cause technique not only systematically prevents the recurrence of unwanted events, but in most cases uncovers underlying predicaments, allowing the company to tackle these too in advance. In fact, the benefits of resolving the root cause are typically greater than the value generated by merely mending the supposedly obvious problem, which led to the incident being analyzed.

To finish off using the aforementioned example: if the company whose employee has been injured used root cause analysis, and as a result implemented user manuals in the factory floor, it could gain any number of benefits, including –

1. Less time training new employees; lower cost of recruitment; and possibly greater confidence among new employees to take on additional tasks.

2. Easier ISO approval, and the opportunity to participate in additional tenders.

Ayal Robotics and Engineering Ltd. roots for root cause analysis, and pride itself in offering LaborSave, a principal material handling solution that resolves many key challenges of factories using granules or powder raw material bags.

Manual bag emptying costs

When using past events, associated with unpredictable cost-tag, to map future risks, it is critical to remember that ancillary costs are always higher than the actual expenses relating to the event.

The indirect costs of employee injury, for example, which may include recruiting, training and compensating replacement staff, injury investigation and plant slowdown, can easily reach 4.5X of the direct costs, according to a study by OSHA. And when considering the opportunity cost of not selling new products and potential fines from regulatory agencies, the indirect costs can easily swell way beyond 4.5X of the direct costs.

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