Transforming Production Efficiency at Land O’Frost with Automation
Formic, a leading provider of robots-as-a-service automation solutions for manufacturers across the United States, has successfully implemented five gantry-style palletizing robots at Land O’Frost’s manufacturing facility in Lansing, Illinois. This strategic deployment has resulted in a remarkable 20% reduction in daily labor-related operating expenses, demonstrating the significant impact of automation on operational efficiency. Notably, this shift has enabled employees to transition from the physically demanding task of manually stacking boxes onto pallets to more skilled roles as robot operators. Formic’s Full-Service Palletizer Rental program has not only optimized end-of-line production but has also enhanced workplace safety and elevated employee skill sets from the outset.
Key Drivers for Automation
Land O’Frost identified several critical drivers for integrating production line automation through Formic. The primary goals included improving employee safety, expediting changeovers in production, and eliminating the need for repetitive training on SKU packing patterns. Given that the company operates multiple SKUs, each product changeover necessitated a new pallet pattern, which previously required constant retraining of floor operators. This process often detracted from time that could have been better spent on tasks aimed at enhancing productivity within the business.
“When I saw the opportunity for automation to eliminate repetitive production line tasks while simultaneously improving our employees’ lives, it was an easy decision,” stated Frank Mejia, Continuous Improvement Supervisor at Land O’Frost. “Formic made the entire deployment process simple. They took care of everything, from training our team on the machines to handling all future maintenance.”
Seamless Deployment Process
Formic’s deployment of the five robotic systems was executed over two weekends, ensuring that production operations remained uninterrupted throughout the installation. The team programmed pallet patterns for all SKUs and provided comprehensive training for all floor operators on the new robotic systems. This meticulous approach not only facilitated a smooth transition to automated processes but also ensured that employees felt comfortable and confident in their new roles.
Driving Innovation and Efficiency
“Land O’Frost has always focused on finding new ways to innovate their production processes, which is how they’ve continually grown since their founding in the 1940s,” remarked Saman Farid, Founder and CEO of Formic. “By adding our palletizing solutions to their production line, they’ve eliminated unnecessary downtime, upskilled employees to robot operators, and reduced overall operational expenses. Automation was the final missing piece in driving their production efficiency even further.”
A Vision for the Future
Looking ahead, Land O’Frost is set to host a Formic Automation Community event on April 30, 2025, at their Illinois facility. This event will showcase how Formic’s advanced robotic solutions contribute to the production of an impressive 128,000 pounds of meat daily. This initiative not only reflects the company’s commitment to innovation but also highlights the transformative power of automation in the manufacturing sector.
Conclusion
The partnership between Land O’Frost and Formic exemplifies a forward-thinking approach to manufacturing, where automation and employee empowerment go hand in hand. By reducing labor-related operating expenses and enhancing production efficiency, Land O’Frost is not only improving its bottom line but also investing in the future of its workforce. As automation continues to evolve, it is clear that companies embracing these technologies will lead the charge in modern manufacturing, setting new standards for productivity, safety, and employee satisfaction.
Source: Formic
