SABIC: Enhancing Safety and Consistency Through Automated Bagging
A global leader in diversified chemicals, producing a wide range of materials used across automotive, industrial, electronics, and consumer applications. The company's high-volume production and distribution operations must deliver efficiency, safety, and consistency to meet customer demand.
Manual bagging and stacking processes created ergonomic risks for employees and variability in pallet configurations, leading to inefficiencies in storage, handling, and transportation.
Project Overview
Manual bagging and stacking processes created ergonomic risks for employees and introduced variability in pallet configurations. Inconsistent stacking patterns led to inefficiencies in storage, handling, and transportation, while manual handling increased the potential for workplace injuries and fatigue.
Automated bagging and palletization
Ergonomic safety and pallet standardization
472,000 bags per year automated with 99.9% compliance
Execution Highlights
Reduce ergonomic risk associated with manual bagging and stacking
Improve consistency in pallet stacking patterns
Maintain or improve operational throughput
Outcomes
472,000 bags per year automated instead of manually palletized, significantly reducing ergonomic risk exposure.
99.9% pallet configuration compliance, reducing palletization defects by over 98% to create highly repeatable, customer-ready pallets.
75% reduction in staffing from eight operators to two while improving safety, consistency, and throughput.
Approach
The automation solution removed the need for employees to manually palletize approximately 472,000 bags per year, significantly reducing ergonomic risk exposure.
Reduced load configuration variability and achieved 99.9% pallet configuration compliance. Reduced palletization defects by over 98%, creating highly repeatable, customer-ready pallets.
The automated palletization solution reduced direct labor requirements from eight operators to two operators, a 75% reduction in staffing while improving safety, consistency, and throughput.
TCG's automated solution improved both the safety of the workforce and the consistency of our operations.
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