GS-MR Robotics
Paula Owen, director, explains how by challenging an historical manual glass industry process, GS-MR Robotics succeeded in developing and patenting one of global manufacturing’s most innovative robotic automated Material Sheet Handling Processes for any manufacturing platform.
So how did GS-MR Robotics, a small, new, robotics company made up of husband and wife, manage to achieve this, particularly when one of us had no glass industry experience?
Even manufacturing experts have windows, but do you know how your windows are manufactured? Do we need to know? Glass is dangerous, we can leave it to the experts, right?
Would it surprise you to discover with the levels of technology available, the latest automated insulated glass unit (IGU) processing lines that manufacture the majority of residential windows continue to rely on a risky manual process as standard? Operators loading and unloading glass of all sizes and weights, including patio door sized, for minimum wage and not much more?
An automated IGU line dependent upon manual labour in key production areas is indicative of where the industry remains, and the industry struggles to recruit?
IGU processing has come a long way in the last 50 years, however, the question remains unanswered, ‘What is the relevance of the industry’s continuing commitment to manual processes which, by design, contribute to producing significant waste?’ Despite the manual processes being adopted more than 50 years ago, where is the promotional video footage?
The unavailability of sustainable solutions only serves as an enabler for creation of avoidable waste; social media posts proudly showing tonnages of cullet (waste) returned for recycling.
Other industries have embraced automation, the lack of sustainable solutions available demonstrates a hesitance that it could indeed secure the industry’s future commercial competitiveness, leaving IGU processors with limited choice to even begin to future proof acknowledged problem production areas.
So along come GS-MR Robotics in 2018 comprising of Robert Owen, background global aerospace and defence engineering, with 12 years in glass processing industry machinery sales, and me, his wife, 30 plus years within commercial IT and administration in the UK, US and Far East, with zero glass industry experience – a fresher on the periphery of an industry most people only ever see through.
And after becoming privy to the reliance on low paid manual labour and PPE, in the pursuit of IGU manufacturing, I am aligned with Robert’s decision – the time for change is overdue.
Regardless of other proven automated systems successfully handling complex commodities, industry feedback to our decision to improve safety and reduce waste was dismissive. Interesting to note the emphasis placed upon a robot possibly breaking glass when operators personally dealt with the impacts of broken glass.
Unphased, we continued to question the relevance of why machinery manufacturers would automate existing IGU processing lines without automating the critical principal function.
Having both worked within multiple manufacturing platforms, considerations continued including how multiple materials reacted to manual and automated manipulation, sheet material tensile strength, how automation had benefitted other everyday industries.
After watching the automated process of mayonnaise production, how a machine can crack an egg cleanly in two, separate and harness content, then dispose of the shell, in under 1.5 seconds, we confidently concluded a risky manual glass handling process with a heavy reliance on PPE could be successfully improved.
In comparison to other manufacturer’s solutions which load unverified glass and require substantial footprints and major capital investment, we instead developed a proactive solution, resulting in the GS-MR PRO:Load.
The PRO:Load verifies glass pane in a stillage prior to loading, only loading upon completion of verification. The glass is loaded on its edge via a special gripper function, thus protecting specialist coatings and eliminating any possibility of a misload.
The GS-MR PRO:Load is the only worldwide IGU loading solution not to incorporate vacuum whilst operating within a substantially reduced footprint.
Designed and manufactured in house by GS-MR Robotics, the PRO:Load performs multiple verifications to extremely accurate tolerances.
It is GS-MR’s patented process that, for the first time within the global glass industry, keeps problems away from the loading area, eliminating avoidable production stoppages.
GS-MR’s PRO:Load has the capability to load any manufacturer’s vertical processing line with any manufacturer’s software platform, significantly reducing costs, whilst increasing HSE benefits.
Our dedication in daring to challenge the norm, and following two prototypes, GS-MR Robotics secured an Industrial Innovation Award in 2024, an award achieved through rigorous assessment conducted by industrial professionals.
Furthermore, GS-MR Robotics have manufactured and patented a multi-functional Material Sheet Handling process that reaches far and wide beyond our original remit of success for the global glass industry; the GS-MR PRO:Load can literally apply itself to any sheet material available for processing, within any industry, such as furniture flat pack sorting, sheet metals, wood, plastics and composites.
It’s encouraging how the glass industry is now shedding its hesitance, not least in terms of understanding the benefits of increased production quality, reduced wastage and reduced CO2 emissions, essential industry targets met head on by the GS-MR PRO:Load.
The fact remains, the patented process of GS-MR’s PRO:Load will have loaded another 3 verified panes during the time it takes to manually remove another unverified misload.
With our latest PRO:Load installations automating manual loading of the latest Lisec Flexible Spacer IG Lines at Press Glass UK’s new high-tech factory in Port Talbot, the benefits of the GS-MR PRO:Load are here to stay. Press Glass UK are the UK’s leading manufacturer of insulated glass units and part of the global Press Glass Group.
Prototypes serve as the ‘monimentum’ of our incredible journey, with the original specification being a fraction of what we have since achieved.
Manufacturing investors today require well designed, sustainable automation. That does not include a process that knowingly produces waste.
GS-MR Robotics
Based in Telford, UK. GS-MR Robotics are not affiliated to and do not manufacture robotic automation solutions for any other machinery manufacturer. GS-MR Robotics design and build customer driven bespoke and production patented industrial robotic automation solutions. The GS-MR Material Sheet Handling Process is patented in the United States, United Kingdom, with further global patents pending.
www.gs-mr.com sales@gs-mr.com
