The CRG Catalyst

For a couple decades, CRG Automation plugged along and did its thing. But then 2019 came calling, and so did the U.S. government. “It was an emergency request, and it allowed us to flex the muscles we’d developed over the years,” said DeSmet. “It became a 4-year journey across multiple products and plants, and we got them to the finish line ahead of schedule despite starting well behind.”

CRG’s contacts on the government job told them what was done in 12 months would have taken five to seven years without them. Accolades from elsewhere poured in as well, with recognition from Time and Fast Company for inventiveness and innovation.

As recognition and growth entered the CRG story, the company has remained a place that says what they’ll do and does what they say. They’re now recognized as one of the top places to work in Kentucky.

The CRG Difference

When asked what makes his company stand out, DeSmet had his answer ready: the people. “We’ve quadrupled headcount since 2019, and because of the urgency of our government project, we needed people who could hit the ground running.”

“That influx changed our company dynamic. We thrive on open collaboration with each other and with our partners. We have seasoned engineers with decades of experience, new engineers fresh out of school, combined with shop technicians that bring ingenuity and hands-on experience to every design.”

With the government work complete, CRG is focused on one key segment: automated packaging. “We’re a system integrator as well as a custom equipment designer and builder,” said DeSmet. “When we approach a project with a customer, it starts with finding out what success looks like for them. After that, we spot the opportunities and develop a solution for the problem they’re trying to solve.”

Who’s Coming To MODEX 2024

At Kawasaki Robotics, a key differentiator is our ecosystem of technology partners thanks to our commitment to staying open, and it is crucial to our promise to design and support difference-making robots. We are thrilled to have CRG accompanying us to MODEX, March 2024 in Atlanta, with a powerhouse technology partner who is paving the way for future proofed automation.

“We are system integrators, which means we bring everything together to build the system – robotics, software, vision, conveyance – everything needed to create a one-stop solution for our customers,” DeSmet said.

We’ve partnered with Olis Robotics, and will feature their proven, edge-hosted software platform. Paired with vision, the software allows users to remotely access their robotic cells to recover any common faults. If you have a robotic tech responsible for 20 robots, they can’t be everywhere at once. But with this software, they’re alerted, they dial in remotely and address the problem.”

The Holy Grail of Warehouse Automation, On Display at MODEX 2024

At MODEX, a Kawasaki BX130X robot will be palletizing and depalletizing mixed SKUs. In front of the BX platform, visitors will see a RS007L robot, which is part of CRG’s automated corner board application system (CBAS). The robot will simulate placing corner boards on the completed pallet, a process that integrates with stretch wrappers and ensures pallet stability during shipping. That robot application will also be monitored by Olis Connects remote monitoring and error recovery software. We will demonstrate what happens if the robot faults. With Olis, an individual can simply recover the robot. And that’s without having to physically be there. Even better.

Long story short, if you and your company have an interest in warehouse automation, you need to get to the Kawasaki Robotics booth at MODEX 2024.

*In case you were wondering, yes, CBAS did indeed get its name from the film Dumb & Dumber.

Jeff Monte, Production Supervisor at Kawasaki Robotics, has a motor like this. We’re thankful he does.

Growing Up & Finding Kawasaki

“I was definitely that kid who wanted to tear things apart and figure out how they worked,” Jeff said. “I went into the military at a young age and served for five years as a mechanic in the Seabees. After my time was complete in the Navy, I became a machine tool electrician.”

Soon after, Jeff got his introduction to Kawasaki robots while building and programming assembly lines for Ford. He made the switch to Kawasaki in 2000 as a contractor in the production group, and was hired direct in 2006. His responsibilities naturally shifted from production to supervision as time went on.

“I knew right away Kawasaki was a great company when I started in 2000,” he said. “Mellow, easygoing environment that was also filled with people who were built like me. I saw right away you could pretty much pinpoint where you wanted to be and grow there.”

Present Day: A Little Bit of Everything

Jeff and his department are known for their ability to help out wherever they’re needed. Consistent parts of their work week include running all robot orders through production—the robots are identified and pulled, worked on and prepared for shipping—facilities maintenance, trade show setup and teardown and plenty more.

“Yeah, robot shipping, supporting the automotive department, paint, marketing, receiving, and the list goes on. It’s non-stop, but we enjoy it. I have a great production team, management and support. Getting through each day with every order and request getting completed correctly and on time is a big accomplishment in itself, and it’s thanks to my team and the groups that support us, that allows this to work smoothly.”

“It’s also really satisfying working the trade shows when the show is over, and everything went well. Over the last 10 or so years, working hard with the marketing team, we have developed a really good system and process for setting up and tearing down our tradeshows.  There’s so much work that goes into it, before, during and after.”

Words of Wisdom

Jeff and his wife have 5 kids that range in ages from 13 to 37, and they already have 12 grandkids to boot. The devoted husband and father has a humble nature, but there’s a lot of wisdom in him. We asked him a couple questions to pick his brain: something about our industry that surprised him at first, and something he wishes he’d have known early in his career.

“The surprising thing was how much work is involved with making a job go smoothly. So many people bring their skills to the table, and everyone does their part. You see an assembly line and think there’s not much to it, but it’s a remarkable thing when you work closely with it.”

“As for something I wish I knew, probably that I didn’t have to solve any problem on my own. I wanted to take things on and solve them, I wanted to be that person, but jobs go so much better if more skilled people are involved. There are always people who can and will help you.”

LIGHTNING ROUND!

Pets: A cat and dog. We’ve always had dogs, and I’m allergic to cats. But four years ago, my daughter heard a kitten outside the window, less than a week old. So we brought it in and you can guess what happened from there.

Movie: Either The Breakfast Club or A Few Good Men. One takes me back to high school, the other is such a great and well-acted story.

Band: Something from the 70s or 80s. KISS, Journey, Pink Floyd, Metallica, The Guess Who.

Travel: I’ve traveled a lot over the years, so I really enjoy taking my wife to new-for-her places I’ve been to before. Alaska, Hawaii, Italy are all on the list.

Drink of Choice: I’m a beer guy, I like many different kinds of beer. I like 312 from Chicago a lot.

Food: Pretty much any seafood that’s cooked. Thai and Chinese food too. I am not a picky eater.

Go-To Restaurant Order: Fish..

What you’re cooking for a surprise guest: If I have time? BBQ from the smoker. If it’s a rush, probably chili. Easy and quick.

Favorite childhood toy: Hot Wheels and Matchbox cars. I loved trying to draw them.

Secret talent: I don’t do it much anymore, but I used to like to dance. We’re not bar hoppers anymore, but we’ll always love music.

I work in the automotive division at Kawasaki Robotics, and I’ve worked directly with a whole lot of products in our lineup. All of them are trustworthy and capable, so it was hard to narrow it down to just five.

But we got there. Here are a handful of our notable difference-making robots, spanning applications from automotive to far beyond.

1. BX200: The All-Rounder

KEY SPECS

• Payload: 200 kg (440 lbs)
• Max reach: 2597 mm (102”)
• Mounting: Floor

APPLICATIONS

• Spot Welding
• Material Handling
• Machine Tending

I’d call the BX our workhorse. Its hollow wrist is perfect for housing cables and hoses, and the strong and lightweight arm makes it ideal for spot welding. So spot welding is a key BX application, but really, it’s tough to pin down just one because of how versatile it is.

I’ve seen the BX used in material handling (the payload capacity is a good size for automotive), machine tending and dispensing, applying sealants and inspection. You can mount a camera on the BX, and it can go to a specific location and compare the data it sees with your model. Excellent for error-proofing.

2. MG15: The Power Lifter

KEY SPECS

• Payload: 1500 kg (3,300 lbs)
• Max reach: 4005 mm (157”)
• Mounting: Floor

Lovingly referred to as Mega Godzilla around these parts, the MG has a surprisingly small footprint despite its impressive size. It uses a ball screw and nitrogen gas cylinder counterbalance design, and special kinematics with 11 swivel points for robot motion and weight distribution, plus 9 motors. Put simply, this 6-axis robot lifts 3,000+ pounds the same way you and I lift our computer mouse, and it does it with 0.05 mm repeatability.

You could give it some spot welding, but it’s not really designed to do that work. The key application for the MG is, without a doubt, material handling. This guy is heavy-duty. We originally designed it for aerospace, but we quickly got a whole lot of requests because of its payload. Customers get not only the ability to lift serious weight; they also get a robot that’s more accurate than they may ever need. The ball screw design makes it very rigid and repeatable.

3. CP 700: The Stack Master

KEY SPECS

• Payload: 700 kg (1,540 lbs)
• Max reach: 3255 mm (128”)
• Mounting: Floor

Being in automotive, this is the one robot on today’s list that I haven’t used. But I’ve heard and I know plenty about it, because it’s a top performer in palletizing.

If you need packaging and stacking, you’ll love the CP. Good payload with impressive speed and very easy-to-use palletizing software.

4. BA013N: The Welder

KEY SPECS

• Payload: 13 kg (29lbs)
• Max reach: 1492 mm (59”)
• Mounting: Floor

As you can tell from the specs, this is a compact and precise robot. Its key application is arc welding, so the heaviest thing on it is sure to be an arc welding torch.

I’ve worked with a lot of welders in my day—and also with a good amount of competing robots thanks to my history as an integrator—and it’s clear that the BA shines because of its feature set. This is probably the most user-friendly and feature-rich option in its category.

5. BU015X: The Seal of Approval

KEY SPECS

• Payload: 15 kg (33 lbs)
• Max reach: 2887.5 mm (113”)
• Mounting: Floor

A sealing robot that sports a 7th axis. Especially useful for getting to places that are hard (or impossible) for 6-axis robots to reach, like the underside of car bodies.

The key perk with the BU is that, rather than having sealer dispensing from a third-party supplier, this robot is fully Kawasaki: seal pump, material and everything else. So if you have a desire for an all-in-one sealing robot, the BU is perfect. It’s all packed in.

No matter your robotic application, there’s probably a Kawasaki robot for it.

Regardless of industry, task or payload, Kawasaki Robotics is known for building and supporting strong, intuitive and versatile robots. Whenever you’re ready, talk to us about your application.

“I was always the #1 student in math,” she said. “I like it much more than language. I think that’s why accounting fits me. Use a number to describe a situation? Yup, that’s me.”

Crunching the Numbers for Kawasaki Robotics

Sue began working at Kawasaki Robotics in 2013, and in the decade since, she has established herself as a trustworthy, hard-working and kind member of the team. Today, our Accounting Team Lead accomplishes tasks with enthusiasm and professionalism, contributing to an overall culture of positivity and productivity.

One of her main strengths is gathering evidence and making appropriate financial decisions. It’s a crucial accounting task that requires deep analytical skills, and she has those skills in spades. “There are lots of different parts of my job, and every day is different,” she said. “Invoicing, corrections, month’s end and closing, cash flows and lots more.”

“My favorite part of the job is honestly dealing with different departments here, and with customers outside our walls. I get answers to my questions, and the constant opportunity to learn and grow.”

Impressive Adaptability

In 2022, the accounting department at Kawasaki Robotics unexpectedly fell to three people for a time. The trio remaining, which included Sue, worked together to make sure things continued to run smoothly. “I took on a number of tasks I didn’t always do, and I still do them regularly to this day. I’m proud of the work that we did then, and I consider it one of my most notable accomplishments in my time here.”

LIGHTNING ROUND!

What Sue likes to do when she’s not working: All kinds of things. Go to the gym, take a class there and talk to other members. Reading, watching TV and traveling.

Book pick: The Great Alone by Kristin Hannah. Anything she writes is a good candidate for my favorite book.

TV show pick: Currently? Suits on Netflix. I love that show.

Top places you’ve traveled to: Puerto Rico, I loved the rainforests. Morocco, Italy, Peru, Alaska. All beautiful.

Top places you’re going to travel to: Vienna and Prague. I’m going next month!

Type of food: Sushi. I definitely prefer fish over meat. I try everything I can.

What you’re cooking for a surprise guest: Simple and delicious food. Rice, fish, green vegetables. All seasoned well.

Favorite number: I don’t have one. I love them all equally.

Word of advice to accounting majors: This job needs accuracy at all times, so be accurate and diligent. Examining the smallest amounts is where you’ll find the discrepancies that ultimately solve problems.

It’s already quite the challenge, but when you factor in staffing issues that persist across manufacturing, that challenge quickly morphs into a problem. How are packaging and palletizing companies supposed to keep pace?

One good answer: robotic automation. And for shops in need of such a solution, they typically find Kawasaki Robotics to be especially helpful, intuitive and sustainable..

This is why the CP Series is such a standout. There are many reasons our high-performance palletizing robots are an ideal choice for your next addition. We’re covering several of them today.

1. Speed Meets Strength

Nova Automation, a prolific robot automation expert and one of our integrator partners, simply refers to the CP Series as its workhorse. With a wide-ranging 180 to 500 kg (397 to 1,102 lbs) payload capacity and industry-leading cycle times, it’s clear that the reputation is justified.

The CP Series has the speed and strength necessary to accomplish serious palletizing work in short order, over and over again. It has a maximum reach of 3,255 mm (128”), plus an industry-best palletizing capacity of 2,050 cycles per hour at a 130 kg (287 lb) payload using the CP180L model.

2. Space and Energy Conservation

The E03 controller attached to the CP Series is an undisputed winner as well. The space- and energy- saving unit is just 25% of the standard palletizing controller size and easily fits under conveyors and other equipment.

This controller generates electric power while in a deceleration mode, reducing energy consumption and minimizing carbon dioxide emissions. It’s a guaranteed way to boost sustainability in your shop as you boost productivity at the same time.

3. That Intuitive Software

Kawasaki Robotics’ software is known to be more open and possibility-filled, and it’s fun and easy to use, too. Our dedicated palletizing software, available as an option, allows users of varying skill levels to quickly and easily simulate layout planning and operations. They can also create robot operation programs on a computer.

4. Our Legendary Support

While our robots, controllers and software have proven themselves to be consistent difference-makers, the team at Kawasaki Robotics has done the same thing. We work hard to be a partner who shoots straight, treats people right and lends exactly the right consultation. There’s a reason we like to say WE ARE NOT ROBOTS, after all.

5. The CP Series is In Stock!

We have a handful of CP units on our floor right here in Michigan, and they are ready to serve. If your business has a need for palletizing you can set your watch to day in and day out, there’s nothing better. Explore the CP Series further or get in touch with us. We’re ready to equip you for today and tomorrow.

In my previous roles, I mostly worked on FANUC robots. I was comfortable and didn’t think I needed to know much else. Then I joined Kawasaki and discovered a whole new world of access thanks to a different, more freeing programming language.

It made me realize I could make our robots do a whole lot more than I could make them do before. Kawasaki has a very open programming language that has a lot in common with computer software. If you like having lots of commands to build different functions, you’re going to love the Kawasaki software.

As you get started with Kawasaki Robotics software, here are 10 tips to keep in mind that will help to quickly gain fluency in this new and exciting language.

1. Create Robotics Programs Offline

K-ROSET is our sim software that lets users troubleshoot, learn and improve. Create robot programs offline and see a 3D version of your robot run your program. Our LITE version of the software is a free way to start using basic features of K-ROSET. You can contact us anytime to get the free version.

2. Access Comprehensive Notes

Kawasaki Robotics has a web page filled with robot manuals, software manuals and training and marketing content. Everything is vetted by our headquarters in Japan, so you can be sure you’re completely up-to-date as you absorb the material. To get access, get in touch with your Kawasaki sales rep.

3. Get More For Less

Long-time Kawasaki Robotics customers know this well, but newcomers are often surprised to learn just how many software options are packed in without requiring additional cost. Collision detection is a big example of one such option. It does exactly what you think: slows and stops the robot before making contact, preventing damage.

4. Monitor the Location of the Robot Tool with Work Zones

Automatically turning on an output lets the controller know that the robot has entered an area of the system, which proves useful when multiple robots are in the same zone. They’re able to tell each other where they are.

5. Get More Consistency with Direct Speed Control

DSC lets you control movement speed in mm/sec instead of as a percentage. So if you want your robot to go 130 mm/sec when it goes to dispense or approach a pick position, you can do that. It’s great for a constant and controlled speed.

Whenever You Have Questions, Bring Them to Kawasaki

All of us at Kawasaki Robotics only know one way to do business: stress-free, collaborative, and with mutual respect. As you build your long-term robotic process automation strategy, we’re always here to help however we can.

6. Solve Singularity Positions

A major problem industrial 6-axis robots have is when joints 4, 5 and 6 are aligned. This is solved with a single line of code in the program that locks joint 4 to zero degrees for specific motion paths. This solution isn’t very well known, but it works wonderfully.

Fun fact: tips 3 through 6 are all included standard in the Kawasaki controller!

7. Capitalize on Background Programming

All robot programs, regardless of brand, go line by line. But at Kawasaki, we also use background logic that runs on the side of the main programs. Handle communication with the PLC, run error handling on the side, and in general, enjoy more logic overall. When people say Kawasaki programming is flexible, this is a big reason why. It’s also why we typically say yes when a customer asks, “Can I do this?”

8. On I and On E

These functions monitor input in the entire robot motion. For On I, as soon as the input turns on, the robot runs a different function. On E is the same, except it’s on error. So as soon as any error happens in the controller, that specific function is run. If there’s a collision or the program faults out, this function talks to the PLC and gives an explanation for what happened.

9. Got a USB Stick or Ethernet Connection? Grab Your Robot Backup.

All programs, system settings and robot configuration, saved in a single text file. You don’t need a special license to read the backup, either. Just take the drive, plug it in and read every program, error log and robot config that’s in there. It’s about 500 kb per text file. Then, plug the backup into your next robot to speed up integration in a big way.

10. HMI Screen, Standard

Every Kawasaki teach pendant comes standard with an HMI screen. It’s usually a costly device like an external PC or table touchscreen on the outside of a cell. But here, that functionality is on the teach pendant itself with the teach pendant touchscreen.

Ready for a Whole New Programming World? Talk To Us!

Kawasaki software might be the most open and possibility-filled option on the market. To see all the additional things our robots are capable of thanks to their programming, talk to us about your application.

Hang on there. Before you leave this page, let me just say I know what you’re thinking: an entire article about long-term robotics strategy? YAWN.

For the record, I fully agree with you. The manufacturing and industrial robotics sectors tend to get ridiculously technical in stories like these, publishing content that’s dry enough to make farmers panic.

It’s funny that so many of us do it that way, isn’t it? Especially considering people often need conceptual instruction rather than reams of technical info.

So yes, this is indeed an article about building a long-term Robotic Process Automation (RPA) strategy. But this one is actually readable, and you might actually take away a couple things.

Rule #1: Start Simple, Start Small

If you’re just starting to work with industrial robots, remember to focus on the basics and the fundamentals. When kids learn baseball, they don’t immediately learn how to hit the cutoff man and throw a slider. They learn where first base is.

It’s the same with any new endeavor. The best (and most cost-effective) way to learn is to start simply and know that you’ll grow your knowledge over time. I’ve seen plenty of horror stories where a company said goodbye to a thought-out robotics strategy and instead dropped seven figures on their first project.

It’s a much wiser move to spend somewhere between $100k and $200k on that first project. After all, you don’t know what you don’t know. You and your team will learn what works best for you that you can take to future projects. Trust me on this one: you won’t know what you want from your first robotic system until after it’s running.

Whether it’s a DIY project or you’ve partnered with an integrator, know that you don’t have all the experience you want yet, and that that’s okay. Each project is a chance to position yourself better for the future.

Rule #2: Diversify Your Robotics Portfolio

This one is HUGE, and the basic truth goes beyond robotics. No matter what the industry is, we all tend to have strong loyalties for certain brands. It’s scientifically impossible to see a Mac user operate a PC without complaint, and vice versa.

In industrial robotics, whether your favorite jersey is yellow or red, a lot of us tend to leave that jersey on and never take it off. But in all honesty, you are doing your company a disservice if you do business that way.

Do I want to see you buy Kawasaki Robotics? Of course! That’d be great. But if I was your brother and you asked me if you should diversify your robot base, I’d give that question a big ol’ affirmative.

Here’s a quick list of pros and cons:

Pros of working with multiple robotics partners

• Protect against shortages
• Keep your suppliers honest
• Get the best deal
• Give employees more comprehensive training
• Move eggs to other baskets
• Benefit from engaged and motivated partners
• Foster rational decision making
• Harness partner strengths and avoid their weaknesses

Cons of working with multiple robotics partners

• Your floor will lose some of its color coordination
• End of list

You diversify your stock portfolio and know that practice to be a wise one. Why not do the same for your business and diversify your base of supply?

Rule #3: Training Needs to Happen Now and Later

Once you’ve chosen your robotics platforms (yes, plural), it’s time to get your people trained. Teach them the basics, and instill into your culture that no one company has a monopoly on the tech you use. Train them on PLCs like Siemens, Allen-Bradley and Omron. Train them on robots like Kawasaki (the best choice in my unbiased opinion), FANUC, ABB, KUKA or Yaskawa.

Doing it now is easier than later, when you have a massive base in place and you’re scrambling to teach everything. Start foundational, progress to advanced and lay the groundwork for long-term sustainability.

Rule #4: Know What You Want from Robotics Integrators

Two options here. The first is doing a lot of it yourself and bringing on an integrator in a consulting role.

They should have experience. They should have successful projects under their belt. But they should also fit naturally with you and your company culture.

Find out what they specialize in, what they’re good at. Partner up with the integrator consultants whose skills and experience match what you’re looking to do.

Find out what size of projects they like to work on. Find out how many programmers and engineers they have. How many mechanical, electrical, PLC experts on staff. This gives you an idea of what their resources are like.

Finally, ask them straight up if consulting is something they’re interested in. If they are, it’s off to the races.

So that’s option one. The second option is the full integration partners that do it all for you. It’s still important that they align with you culturally, but now it’s vital to focus on the application.

If, for example, you know that you’re only going to be palletizing, you may not need more than one integrator partner. But if you plan to execute a variety of projects, you’ll probably want more than one in the stable.

As you work with them, you’ll notice that Integrator A is really good with this specific application. Integrator B brings a ton of expertise, but they’re too expensive for the simple projects.

Looks like I went back to diversification again. To be fair, I can’t help it. It’s clearly the smartest way to do it. The more integrator partners you get to know now, the more you’ll understand their capabilities for future projects.

Whenever You Have Questions, Bring Them to Kawasaki

All of us at Kawasaki Robotics only know one way to do business: stress-free, collaborative, and with mutual respect. As you build your long-term robotic process automation strategy, we’re always here to help however we can.

Talk to us anytime. Doesn’t matter if you already have a robotics partner. We’ll gladly contribute to your diversified portfolio.

I encounter this question often enough over the course of my week that I figured I’d park it in the chair and write a full guide. If you’re wondering what the difference is between fixed automation and flexible automation—and which is the best fit for you—get ready to scroll for a bit.

What Is Fixed Automation?

Put simply: fixed automation, also known as hard automation, is automation without a robot. It covers anything that is generally not flexible to changing orientation, adapting for multiple SKUs, or programmable as a single unit.

Instead, fixed automation is a system using servos, standalone servers, linear or rotary actuators, separate sensors, and programmable logic controllers (PLCs) all integrated into one system.

Benefits of Fixed Automation

Want to go fast above anything else? Fixed automation is for you. It tends to be faster than any other option. We robotics folk don’t love to admit that it’s faster than robots, but it’s true. Go to tradeshows and see actuators, they’re moving at wild speeds. I’m talking sub-one second cycles.

On top of the speed, actuators and servos are available and relatively cheap. A lot of footprinting is standardized as well, and it’s easy to plug & play with a lot of different fixed automation components.

A couple more perks while we’ve got momentum: simplicity and robustness. A good PLC programmer doesn’t have to break a sweat to get fixed automation doing what it needs to do. It’s not overly complex. And in terms of robustness, breaking a part generally isn’t a huge deal because you probably have the spare part on the shelf.

Bottom line: good variety of product to choose from, fairly low cost, simple and robust, and mood-boosting speed and accuracy. Fixed automation is a great option for some. But not for all, because:

Weaknesses of Fixed Automation

Pretty simple: it’s not flexible. You might be able to move things a bit, but if flexibility is a key need for your application, you’ll have to look elsewhere.

We just mentioned that fixed automation is fairly easy to program, but the build of the fixed automation system itself can be tremendously complex. What’s more, there’s no manual for that system. The only people who know how it was set up are the people who built it in the first place.

Flexibility is honestly the biggest downside of fixed automation. But wouldn’t you know it, there’s a fantastic option for anyone who craves that flexibility.

Benefits of Flexible Automation

By now you’ve guessed what the key benefit is here, but I’ll say it anyway: that flexibility. Having the ability to use one robot on different products is a huge plus, and for high mix low volume environments, it’s downright huge.

As the years have progressed and robots have improved, their durability and robustness have grown to mimic fixed automation. They don’t tend to break unless accident or neglect happens. Their repeatability is good, but not as strong as some actuators. Flexible automation has too many things pulling other things around, and last I checked, physics is undefeated.

HOWEVER. For your application, you may not need repeatability as much as you need flexibility. Complete a job, and you can easily move that flexible robot to the next task. It’s a game-changer for HMLV facilities.

Weaknesses of Flexible Automation

Even the shiniest and toppest-of-the-line robots are bonafide boat anchors until someone tells them what to do. And programming that robot to capitalize on its flexibility takes real work.

But the good news is once you tell the robot what to do, it’s going to do that job consistently and without complaint for as long as you need it to. A robotics partner worth your time and budget will also provide with all the training materials you need to speed up the learning curve.

And of course, if speed is important, flexible automation might not be right for you. A good rule of thumb: if you want to move something heavier than 5 pounds in less than 5 seconds, flexible automation is probably too slow.

Where to use Fixed Automation

Use fixed automation on long runs of consecutive single-SKU or dual-SKU products that run for a REAL long time doing the same thing, over and over.

Couple examples: row after endless row of oil filters or food packaging coming off a conveyor line. Pick ‘em up, put ‘em over here.

A very real possibility: you might need both

We’ve implemented plenty of systems where flexible automation works closely with fixed automation. A whole lot of facilities see major benefits from doing what each system is good at: they get the speed and cost-effectiveness of fixed automation, combined with the flexible nature of robots.

Closing

You may already know this answer based on your application, but here’s the key question: which do you need: speed and repeatability, or flexibility? That answer will tell you whether you should pursue fixed automation or flexible automation.

If you have additional questions or want to know more about an application-specific offering from Kawasaki Robotics, contact us any time. We love nothing more than talking this stuff over.

All of those attributes and more describe Stephanie Evans. She’s had many roles and responsibilities in her decade at Kawasaki, and she’s succeeded with each one because of her consistent mindset: she truly loves making people happy and seeing them smile.

The Start

Stephanie found us just about 10 years ago through a contracting company. “I applied, came in and interviewed, and by the time I was halfway home I had a call from the recruiter saying that Kawasaki wanted to hire me. I worked through the contractor for the first year or so, then got hired directly by Kawasaki.”

She spent her first four years in Shipping & Receiving, which was heavy on manual labor. “That was hard work and a good workout for sure, especially on hot days,” she said. “I’d scan everything in, make sure it all matched up, put it on the shelves, and Inventory would take it from there.”

From there, Stephanie moved to Refurb & Repair. “To this day, that job is like my little baby and I don’t want to let it go. Usual tasks there include quoting customers, getting serial numbers and as much info as possible, then receiving parts, converting POs, and giving everything to our refurb techs.”

How Stephanie Stands Out

It’s at this point that we get to little details that show why Stephanie makes such a big difference. One thing she implemented: customer appreciation for Kawasaki customers who went through Refurb & Repair.

“It’s nothing huge, but when the work is done, I like to send customers a bag of candy thanking them for their business. I noticed a couple customers doing that when I worked in Shipping & Receiving, and I really liked it. Those little unexpected gifts make a big difference.”

Today, while still staying involved in Refurb & Repair, Stephanie is Executive Admin as well. “I work closely with our service techs in that role,” she said. “They’ll quote a customer, and I’ll order parts and get them on the schedule. Once the work is done, they hand in expenses, field service reports, receipts. I process all of it and bill the customer. It was a little chaotic when I started but I’m proud to say it’s running smoothly now.”

16 years ago, Stephanie’s sister got married. Through that process, Stephanie discovered a love for event planning. She still does that on the side when people need it. The skill has come in handy for us at Kawasaki Robotics as well, both in her everyday roles and for special events.

“We have a KawaService conference every year, and just this past year we went to Louisville as a group for the week,” she said. “So I help organize that, choose activities, find hotels, stuff like that. There’s lots of conference time and training for our service techs, but we also managed to do a bowling/arcade outing, a session at Top Golf and a boat tour up the river.”

How Kawasaki Stands Out

We asked Stephanie when she realized she wanted to work for Kawasaki long-term, and she said the moment was a little more recent. 

“It was when Mike Dawson (Manager of Service & Production) and Darrin Stewart (Director of Service, Supply Chain & Production) joined us,” she said. “When management comes and goes, it’s hard to form those personal relationships that help it feel like more than a job. But in the last few years, you can feel that Service definitely feels more like a family here. 

“Everyone’s ideas are listened to, and we all work together to get the work done better than we ever have before. And we find ways to have fun, too. Could be our KawaService conference, or a picnic, or a Tigers baseball game. I give a lot of credit to Darrin and Mike for changing the atmosphere and culture on the service side.”

LIGHTNING ROUND!

Family: One son, who’s 19. I like to tell him that he’s my favorite. He recently figured out what he wants to do with his life: accounting! I said go ahead, I need someone to handle my finances.

What Stephanie’s doing when she’s not working: In the summer? Drinking wine on the patio. In the winter? Drinking wine while binging some TV.

1 TV show pick: Definitely House of Dragons, the prequel to Game of Thrones. Can’t wait for the 2nd season.

1 band or artist pick: I’m a blues kinda girl. Actually going to a blues concert on Saturday. My favorite artist right now is King George.

Secret talent: I went to bartending school and can probably make your favorite cocktail exactly how you like it.

Best place you’ve traveled to: Dallas, Texas. I almost moved there. I loved the rodeo, the food, oh my goodness, the food. The people there were so kind, too. 

Drink of choice: It’s actually not wine. I love Old Fashioneds, so I ride with bourbon. I can tell when bartenders are holding back because I’m a woman. I’m like, “Nuh-uh. Make me a REAL Old Fashioned. I can take it.

Drink you won’t ever have again: A mojito. Not for me. The mint throws me off.

Type of food: Mexican, hands down

What you’re ordering from your favorite Mexican place: Tacos and margaritas. Today is Taco Tuesday, so you can bet I’m doing that later. My favorite place around here is called El Nibble Nook. Amazing California-style tacos. Spicy shredded beef, spicy salsa. It’s so good.

Thing you’ll always be terrible at no matter how often you try: Probably bowling. I can roll it, but which way it’s gonna go? No idea.

Word of advice to people just starting their careers: Just be patient and take it a day at a time. All good things really do come to those who wait. I don’t have a college degree, but I just had patience and worked my up to a position I really wanted to be in.

The NOVA Start

NOVA Automation got its start in the mid-1990s when the founders had the urge to return to Denver and serve a customer base that wasn’t being fully taken care of. The reason for starting the company then was the same as the vision now: to give the packaging industry robust and durable industrial automation.

“We started in palletizing, and we’ve since grown into bag filling, stretch wrapping, and conveyance,” said Paul Wegman, CEO of NOVA Automation. “The end-to-end systems we build are incredibly robust.”

“When my business partner and I purchased the company in 2018, we did so because it was such an exciting opportunity. The NOVA products and projects were a solid foundation, and there was an opportunity to make things even better. Today, we’ve simplified our machines to make them very easy for less experienced operators to run.”

The NOVA Difference

NOVA stands out from other automation providers in a couple of ways. The first is something Wegman covered. “We’re an end-to-end manufacturer here, meaning every product that ships out of our facility, we control the design, the manufacturing, the control system, the testing, all of it. So, we have incredible flexibility to respond to customer needs. We can do business at a pace that’s much faster than others.”

The second difference-maker is one we’ve noticed firsthand on a regular basis: NOVA truly listens to customers and partners. Not only does this practice help to build long-lasting relationships, it also guides the kind of product innovation that’s only possible when you’re paying close attention.

The Mobile Palletizing Cell

For proof that NOVA listens and responds better than most, look no further than the company’s MPC Series. “What we were hearing from the market was that there was a need for collaborative robots in palletizing,” Wegman said. “But in speaking to customers, it didn’t make much sense. What they actually needed was a stronger and tougher industrial robot, but also with a small footprint that was mobile and easy to use.”

The MPC Series was developed and launched as a result. Plug, Play, Profit is the language NOVA uses to market the product, and it’s no joke. The programming is already done before it arrives, and it’s paired with an intuitive user interface with an HMI that’s ready to go—plus the NOVA Pallet Builder, which lets users build new pallets on the fly without touching the robotic pendant. It’s a fully enclosed and forklift-moveable cell, ready to rock right when it comes off the truck.

“A person is never going to help a robot palletize, so people didn’t need cobots, as it turns out. They needed industrial strength and speed in a small form factor that was easy to set up and operate,” Wegman said.

Kawasaki + NOVA

NOVA has used Kawasaki Robotics offerings for many of its product lines for close to 15 years. Wegman didn’t discover what Kawasaki was all about until later, but the symmetry was immediately apparent.

“I knew a lot about Kawasaki as a motorcycle and ATV manufacturer, but I didn’t know they were in robotics until I got to NOVA in 2018,” he said. “What I learned was, Kawasaki makes an awesome product we’ve had a great track record with.”

“But what really makes them different is the way they support us and our customers. They really do treat us like we’re their best customer. That support we get is far more important to me than just having a great product.”

Kawasaki’s CP Series: NOVA’s Workhorse for Palletizing

NOVA specializes in solving complex packaging automation challenges for customers who have a wide range of speed and product demands. Robust robotics solutions require robust robots, which is why the company leans heavily on the CP Series of palletizing robots from Kawasaki.

“The CP series is our workhorse,” said Wegman. “It’s a robot we’ve been selling for over 12 years that has stood the test of time in the harshest environments and continues to perform day in and day out.”

The CP Series sports an impressive payload capacity, plus industry-leading cycle times, a maximum reach of over 3 meters, and a 2,000+ cycle-per-hour palletizing capacity. Its versatility makes it an ideal fit for palletizing, where customer needs vary widely.

Building the Culture

On the subject of how NOVA stands out from other manufacturing companies, Wegman and his colleagues have worked hard to build a business with a healthy, collaborative environment that people want to return to.

“First of all, it’s just fun to see everything that’s going on here on a daily basis,” he said. “Go on our floor today and you’ll see seven projects being tested with robots running. Our team isn’t making 10,000 widgets per day, either. They actually get to see the product from start to finish, then again in the real world.

“We also try to bring in a lot of compassion, awareness, and mindfulness. These past few years have been hard in a lot of ways, so we brought in a certified mindfulness teacher to show us how to meditate, and to teach some compassion and vulnerability exercises. It makes for pretty powerful moments, and we still use the exercises here on a regular basis.”

The Future of NOVA

“We’re at an awesome and exciting spot in our journey. We’ve proven that our processes can scale and are profitable, and we know now that this is a viable business that’s ready for even more growth,” Wegman said. “A building expansion, growing our staff, finding more space in Denver to build and test, all of that stuff is on the table.

“When I first started here five years ago, people still saw us as job killers. But now it’s shifted. Companies can’t meet their output needs alone, but we can help with that. We’re taking people out of dirty, harsh environments that are prone to ergonomic injuries and giving them the freedom to pursue better, safer jobs within their company.”

One thing we know for sure: NOVA will be listening closely and developing industrial packaging solutions that actually solve a need that manufacturers have. It’s why we’ve worked with them for so long, and why we’ll work with them for years to come.

If you, like NOVA, have a clear need for high-speed industrial palletizing robots, read up on the CP Series from Kawasaki. We have robots in stock and ready to unlock automation benefits at your facility.