Robotic pallet assembly cell eliminating manual nail gun handling, enabling 5-minute product changeovers across three SKU variants.
Canopy's pallet production depended on manual nail gun operation — repetitive, physically demanding work with real injury exposure. Setup times between product variants were long enough that short runs weren't worth running, so the operation defaulted to large batch production to spread that overhead across more units.
That constraint made the business less responsive. Smaller orders either got turned away or ran at a loss. And the safety concern wasn't going away.
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7robotics designed and built a robotic pallet building system handling nailing and stacking automatically across three SKU variations — with room to add more as Canopy's product line grows.
The tooling includes drop detection, product presence verification, air pressure feedback, and automatic nail gun lubrication. Three safety zones allow forklift unloading to run simultaneously with robotic nailing and stacking — no production stops. An area scanner manages turntable rotation safely, and a safety air valve releases pressure when the cell isn't running.
The HMI gives operators product selection, nail depth adjustment, stack counters, and job-lifetime nail counts. Remote access via wireless cameras and virtual twin technology lets the 7Robotics team monitor and support the cell without a site visit.
Within months of going live, Canopy saw measurable gains across safety, throughput, and operational flexibility. The work that most directly exposed employees to injury — manual nail gun handling and manual pallet stacking — is now fully automated.
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