When a leading FRP manhole and trench cover manufacturer needed to improve consistency, quality and safety within its trimming operation, Adelphi Automation developed a fully automated robotic trimming cell. By replacing a highly variable manual process, the solution delivered predictable cycle times, improved product quality and a scalable platform for future growth.
Key Outcomes
- Consistent and repeatable trimming cycle times
- Improved dimensional accuracy and product quality
- Reduced operator dependency
- Enhanced workplace safety
- Scalable production for future growth
The Challenge
Manufacturing FRP manhole and trench covers involved a labour-intensive manual trimming process that created inconsistency across production. Performance was heavily dependent on operator skill, making it difficult to maintain predictable output and repeatable quality. The manufacturer faced several key challenges:
- Variable cycle times - Trimming times ranged from 2 to 12 minutes per component, depending on the operator and application.
- Inconsistent product quality - Manual finishing processes resulted in dimensional variation and inconsistent tolerances.
- Limited product scalability - Future business growth was restricted by the availability and performance of skilled operators.
- Health and safety risks - Operators were exposed to a dust-heavy trimming environment for extended periods.
The Solution
- 6-axis robotic trimming system - An industrial robot paired with an air-driven trimming and deburring spindle, provided precise and repeatable material removal.
- Optimised product handling - The robot's reach and articulation were configured to process the largest product variants, without additional manipulation, simplifying operation and reducing cycle time.
- Vision-based product recognition - A camera based vision system automatically identifies the loaded component and selects the correct trimming programme, reducing setup requirements and improving flexibility.
- Flexible PLC control - PLC-based control architecture provides a future proofed platform that can be integrated with upstream and downstream manufacturing processes.
- Industry-proven tooling - A widely adopted trimming and deburring spindle was selected to ensure reliable operation, high quality finishing performance, and reduced maintenance requirements.
The Results
- Consistent throughput - Previously unpredictable cycle times were replaced with repeatable and reliable processing, reducing the impact of operator variability on productivity.
- Improved product quality - Repeatable robotic trimming paths delivered tighter process control and greater consistency across finished products.
- Increased operational efficiency - Reduced dependence on manual labour simplified production planning and resource allocation.
- Enhanced workplace safety - Automation significantly reduced operator exposure to trimming dust and debris, creating a safer working environment.
- Scalable production capability - The system enables the customer to introduce new products, adapt tooling and increase output without proportional increases in labour requirements.
Why this matters
This project demonstrates how robotic automation can transform traditionally manual finishing processes. By combining robotics, vision systems and intelligent control, manufacturers can improve quality, reduce production variability and create a scalable platform for future growth.
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