Table of Contents
Upon entering the Land O’Frost facility in Lansing, Illinois, visitors are immediately struck by the bustling activity. Forklift trucks zip around, pallets are wrapped, and workers are busy packaging deli meats and hot dogs. With 128,000 pounds of meat being packed and shipped daily, efficiency is key.
A unique aspect of the facility is the harmonious collaboration between humans and machines. Each step of the packing process is optimized to leverage the strengths of both manual labor and automation. The staff is not only highly knowledgeable but also incredibly friendly.
Frank Mejia, the head of continuous improvement, emphasizes that automation at Land O’Frost is aimed at improving the work life of employees.
Founded on Innovation
Established in 1941 as a cold storage business, Land O’Frost has evolved to offer deli meats, sausages, and premium hot dogs. A third-generation family-owned business, it originated in Chicago and now employs over 1,500 individuals. Founder Antoon Van Eekeren’s son, Paul Van Eekeren, played a pivotal role in designing machinery for the company.
Land O’Frost has a rich history of innovation, with Paul Van Eekeren introducing manufacturing machines in 1975 to enhance production dynamics, reduce labor costs, and improve food safety. In 2016, the company partnered with RedZone to implement lean manufacturing principles and boost plant productivity. Automation was the final piece in enhancing production efficiency.
Continuous improvement engineers like Frank Mejia have focused on automating repetitive tasks to drive ongoing success at Land O’Frost.
Drive to Automate for Improved Working Conditions
Frank Mejia meticulously analyzed the production and packaging processes at the facility to identify repetitive tasks suitable for automation.
One area of focus was palletizing, which involved strenuous box stacking. By automating this process, labor resources could be reallocated, operational expenses reduced, and working conditions enhanced.
Manual palletizing also posed challenges during product changeovers, especially with varying SKUs. Training new line workers on different pallet patterns with each turnover was a significant operational hurdle.
Palletizing Robots Enhance Operations
Key requirements for palletizing cells at Land O’Frost included fitting within limited space, stacking efficiently, and facilitating easy training and product changeovers.
To address these needs, Land O’Frost partnered with Formic to deploy 5 gantry-style palletizing robots. These robots can handle up to 12 picks per minute and have successfully stacked thousands of cases. Formic not only designed and installed the robots but also trained the staff to operate them.
With minimal downtime and significant labor savings, the automation solution has streamlined operations at Land O’Frost, allowing employees to focus on other improvements.
Automation has not only simplified changeovers and optimized labor allocation but has also resulted in a 20% reduction in labor-related operational expenses for Land O’Frost. With the Formic robots handling palletizing tasks, employees can now concentrate on other critical aspects of the facility.
As Land O’Frost continues to innovate and enhance its operations, automation plays a pivotal role in driving efficiency and productivity.
Discover how robotic automation can revolutionize your operations without upfront costs or risks. Learn more here.