Case Study: Newell Brands achieves 99.8% kit accuracy and improved productivity with Bastian Solutions' 10‑Robot Robotic Packing System

Newell Brands - Customer Case Study

Newell Brands, a leading global consumer goods company, was manually assembling Rubbermaid product kits at its 850,000 sq ft Mogadore, Ohio facility with 15–20 operators. Seeking greater consistency, shipping accuracy, improved operating margins, and higher packing productivity, Newell Brands engaged Bastian Solutions to design and implement a robotic kit‑assembly system.

Bastian Solutions delivered a turnkey robotic solution — including a product denesting device, 10 FANUC LR‑Mate 200iD robots with a custom end‑of‑arm tool changer, Zipline conveyors for process and rejects, a hopper for lids, case erector and automatic taper — to automate kit assembly. The system now handles about 80% of kit volume, achieves 99.8% correctly assembled kits, runs one or two lines at roughly 800 and 600 parts per hour, eliminates manual part‑quantity handling, improves ergonomics and has increased operating margins through productivity gains.

Newell Brands