New automation technologies that have matured over the past five to 10 years provide critical capabilities for confectionery and snack manufacturers working to navigate post-pandemic headwinds while building a strong foundation for long-term competitiveness. Technologies that have long been considered experimental have quickly emerged as economical solutions in widespread business use, and now is a great time for manufacturers to take a second look at solutions they may have dismissed as experimental or overly costly in past years.
How can you assess which approach to automation will offer the greatest return on investment (ROI)? You need to have the data; plants with the right systems can track and measure virtually any operational variable. Sensor and computing technologies have advanced significantly, and many facilities have opportunities to dramatically expand the digital integration of their operations. Faster, more ubiquitous computer networks help digital processes run smoothly while providing the data needed to support continuous improvement. Leveraging a system such as AVEVA PI System, Ignition IIoT or Rockwell Automation’s FactoryTalk can help manage this process. These technologies are critical for rapidly and accurately determining the root cause of operational chokepoints, collecting and analyzing the associated data, and determining a solution.
These tools offer the insights needed to streamline workflows and economize on labor, working up from individual tasks to complex processes using the same automated solution. Begin by measuring key variables such as cycle times for each process in the facility. This data can be used to assess the performance of key processes and whether their inputs are functioning as designed. Data collection is instrumental to identifying the times and situations in which a process is not meeting its intended parameters. More granular cycle time data can help drive continuous process improvement and assess the impact of potential process changes. For example, when filling a mixer, are all requisite streams arriving in time for all products being produced? What if a new milk powder is bridging, and therefore dosing takes three times as long?
Maintenance issues are another area where foundational data gathering can uncover opportunities for operational improvements that can drive substantial value. For example, manufacturers should gather the data to quantify how many times a valve can be operated before it fails, and how much it costs if the line goes down. This data is critical for balancing the risk of failure against the cost and savings of proactive part replacement. In general, the cost of preventive maintenance is 10% of the cost of breakdown maintenance, and leveraging the data needed to make preventive maintenance truly predictive has the potential to unlock enormous value.
Once this foundational data has been gathered, it can be aggregated into dashboards that help translate analytics-based insights into actionable operational intelligence. By putting critical, role-specific data at the fingertips of decision-makers throughout the organization, dashboards help all personnel benefit from more granular insights. Moving forward, this data should be used to inform decisions on where to invest capital and operational resources.
New Automation Technologies Large and Small
The term “automation” can conjure images of massive robotic assembly lines, but it is important to bear in mind that effective automation solutions can range from autonomous vehicles to small-scale process automation tools. While full-scale automation requires more substantial investment — and offers even greater potential savings — semi-automated solutions can offer an avenue to labor cost savings without a large upfront capital outlay. They can begin driving value without the same level of intensive planning required by full automation and can function as proofs of concept for broader, long-term automation initiatives.
As one example, Keyence offers an artificial intelligence–based solution that uses a 3D-vision system for sorting and scanning. Its robotic systems can be used for the automation of routine work such as assembly, de-palletizing and machine tending. Even in a facility that is not ready for full-scale automation, automating select workflows can eliminate chokepoints, boost throughput, and shift skilled labor time from monotonous tasks to work that requires human judgment.
Virtual Reality-Powered Planning and Verification
Solutions that utilize virtual reality (VR) have rapidly advanced from expensive and clunky to economical for widespread business use. VR-capable computers have decreased in price, and headsets now cost around $300, thanks to greater commercialization, while wireless connectivity makes deploying these systems far easier.
Why use VR? Consider the difference between viewing a two-dimensional plant blueprint versus a dynamic and malleable blueprint in 3D. Operators immersed in a 3D environment can more easily spot issues that would be difficult to recognize “on paper” (or a traditional monitor). More advanced VR setups with hand tracking even enable operators to physically manipulate virtual items (e.g., simulate product movements). VR can be a great option, for example, to verify the fit of a new solution before investing the full amount needed to develop and implement it at scale.
Automated Material Handling and Warehousing
Advancements in robotics, vision systems and machine learning have opened up a number of automation use cases, both in the warehouse and in general material handling applications. Robots are now used in a wide variety of “piece-pick” order fulfillment applications. Robots offer speed, flexibility and adaptability; line changeovers can be as simple as changing out a vacuum gripper.
“Cobots” are robots designed to work safely in close collaboration with humans. Since their introduction in the early 2000s, cobots have been successfully deployed by manufacturers across a range of applications. One of the most mature applications is case palletizing; OEMs and integrators are developing cobot systems that can be deployed out of the box and set up in a matter of hours.
Automatically guided vehicles (AGVs) are another example of a key automation-enabling technology reaching maturity after years of experimentation. This concept has been around since the 1950s, but these vehicles’ capabilities have dramatically expanded in recent years. AGVs are now capable of operating as truly autonomous mobile robots (AMRs) by leveraging technologies such as lidar and vision sensors, which enable reliable, safe operation even in a busy, dynamic and ever-changing environment like a warehouse or factory floor.
AGV/AMR systems can be combined with automatic storage and retrieval systems (ASRS) to automate virtually the entire end-to-end workflow in a warehouse. Crane-based ASRS systems have been around since the 1960s, when they were developed to manage heavy pallet loads. In the years since, this technology has been honed to accommodate smaller, lighter loads at much higher speeds. With advancements in equipment, sensors and software, these systems are now able to work with an increasingly wide range of loads, delivering improved accuracy and throughput compared to traditional manual operation while saving labor costs.
Completing the warehousing workflow, automated truck loading systems are capable of increasing trailer loading capacity through a given dock by 200% to 300%, using cameras to scan pallets and route them to the appropriate vehicle. This capacity boost can reduce both the number of docks and the labor required to support shipping operations.