AUTOMATION & AI
The hidden bottleneck in warehouse operations Warehouse automation is usually associated with highly visible technologies, from autonomous mobile robots to automated storage and retrieval. However, the pace of an inbound operation can still be determined by something far simpler: how quickly and safely employees can open cartons arriving on the conveyor.
By Nigel Smith, CEO of TM Robotics O
pening a carton appears straightforward in isolation. Repeated hundreds of times an hour, however, it becomes a variable
process involving manual handling, sharp tools and pressure to keep goods moving. Box dimensions, board thickness, tape position and contents can change from one carton to the next. This is why operators must adjust their technique while working at the speed of the line; a blade inserted too deeply can damage stock, while an incomplete cut can delay lid removal, decanting and put-away. These factors can impact speed of production, along with several others identified by the Warehousing Education and Research Council (WERC). They include dock-to-stock cycle time and the number of lines received and put away per hour, both of which are used to assess the efficiency of inbound warehouse operations. Manual carton opening affects both variables by making them dependent on operator speed, carton variation and cutting-tool changes.
Aside from production line speeds, we must also consider workers’ safety. Health and Safety Executive (HSE) figures show that handling, lifting or carrying accounted for 17 per cent of employer-reported non-fatal workplace injuries in Great Britain during 2024-25. The HSE’s hand-knife guidance also advises businesses to eliminate manual cutting through automated methods where reasonably practicable. These guidelines particularly impact carton opening which, of course, combines repetitive material handling with regular use of cutting tools.
TARGETING OVERLOOKED PROCESSES All of these pressures explain why warehouse businesses are examining smaller processes alongside major automation projects. In a survey of logistics and supply-chain executives, McKinsey & Company found that 70 per cent planned significant automation investment over five years, with speed, process stability and reduced labour dependency among their priorities. It also identifies tasks involving high labour hours, repetition and injury risk as strong candidates for automation. Carton opening fits that description. It is
repetitive, difficult to standardise and positioned early enough for delays to affect every stage that follows.
Rather than redesigning an entire facility,
operators can target a defined task while retaining existing conveyors, software and downstream
28 July/August 2026 Irish Manufacturing
equipment. Yet, automated carton opening requires more than replacing a hand knife with a fixed blade. A system must identify each carton, measure its dimensions, calculate a cutting path and respond safely to material changes or obstructions.
A REAL MACHINE-BUILDING APPLICATION
This challenge has already been addressed in a real original equipment manufacturer (OEM) development project. Automation specialist CASI worked with TM Robotics, its UK and European sales partner, and Shibaura Machine to develop the CASi-IBOD, or Intelligent Box Opening Device, an inline alternative to manual carton cutting. TM Robotics and CASI have worked together for more than 15 years, with the former company leading customer engagement and providing local technical support. The CASi-IBOD is equipped with a SCARA
robot for its rigidity. TM Robotics helped customise the robot’s internal parameters, programmable logic controller settings and cutting algorithms. Photoelectric and displacement sensors measure each carton before cutting, while torque monitoring helps detect resistance from heavy tape, staples or difficult board. Real-world applications have demonstrated that
the CASi-IBOD can cut carton tops at up to 500 boxes per hour while reducing product-damage
risk. Current configurations are specified to process up to 550 boxes per hour, rising to 950 in a duo arrangement with automated lid removal. The system can also process mixed box sizes
in any order and apply three-sided, four-sided or customised cutting patterns. Blade monitoring warns when the tool begins to dull, while light curtains, impact sensors, emergency stops and safety tunnels separate employees from the cutting area. The value lies not only in speed. A controlled cut can protect carton contents, reduce stoppages and create a predictable flow into decanting, storage or production.
REDESIGNING AN OVERLOOKED TASK The strongest automation opportunity is not always the most complex or visible. It may be a routine process accepted despite consuming labour. Advanced systems like the CASi-IBOD show
how redesigning one overlooked task can support the wider warehouse. By controlling the first stage of decanting, operators can improve safety, protect inventory and create a more predictable route from dock to stock, returning attention to the simple process that can determine the pace of everything that follows.
www.tmrobotics.co.uk/press-releases www.irish-manufacturing.com
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