Achieving 24/5 Autonomous Production with Vention's Rapid Operator AI

In high-volume manufacturing environments, production lines frequently rely on operators to manually retrieve bulk components from large containers to feed downstream processing equipment. Spanning three shifts per day, five days a week, this repetitive task increases operational costs and introduces risks associated with ergonomic strain, employee dissatisfaction, and turnover. To modernize operations and improve workplace standards, the client sought an automated solution capable of picking unstructured plastic components across a high-mix SKU catalog without requiring major floor layout changes or continuous manual oversight.

To automate deep bin picking, Vention deployed a Rapid Operator AI cell, combining modular hardware, smart motion, and advanced AI perception into a single platform.

Using NVIDIA Isaac™ foundation models integrated with the GRIIP™ Pipeline, the system’s vision engine analyzes jumbled plastic components in deep containers, identifies optimal pick points, and navigates around obstacles without requiring rigid mechanical part positioning. Designed in Vention’s cloud-based MachineBuilder™ platform, the physical cell includes a long-reach collaborative robot inside a guarded safety enclosure, an automated multi-bin tilting mechanism to keep parts accessible, and a custom regrip station to verify part orientation. Managed by the MachineMotion AI controller, the entire cell, from vision and motion to digital communication with downstream machinery, is easily operated through a single interface on the robot pendant.

The Rapid Operator AI cell successfully automated the unstructured deep bin-picking line across multiple SKUs. Supported by the GRIIP™ Pipeline, the AI vision engine reliably identified and processed varying part geometries across continuous production shifts. In testing across primary high-volume SKUs, the system completed over 1,300 continuous cycles in an 8-hour shift with a part drop rate under 0.4%.

The multi-bin feeding design supported 24/5 autonomous operation and reduced direct operational costs by 50% per station. Achieving target cycle times across the entire product catalog, the automated cell generated substantial recurring direct operational savings per station. Integrated cloud connectivity via MachineAnalytics and RemoteSupport provides real-time access to operational metrics, cycle times, and cell status.