april launch event - how will robotics & automation change food processing?
TRANSCRIPT
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How will robotics and automation change food processing?
National Centre for Food Manufacturing, 28/04/16
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Mega TrendsHealthConvenienceChoiceSafety & Trust
Highly Price SensitiveRetailers price war with discounters
The Market:Consumer Driven
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Impact on manufacturing?Productivity vs Uncertainty
• Ever-increasing diversity of products requiring greater flexibility.
• Lower relative volumes of each product line, more SKUs.
• Fierce competition.• Increased compliance requirements,
traceability, audits etc.• Impact of living wage.
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• Cost pressures
• Flexibility
• Traceability
• Food safety
• Waste
• Adaptability
Why automation? Flexible but low costSolving food manufacturers’ biggest challenges
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"Whilst we are very innovative ... where can I see it operating""We would need to initially run the process in parallel to ensure continuity of supply" "Brilliant however we have got too much going on to look at it seriously““Finding suitable space within the current factory layouts will be challenge, can we stick it on the 3rd floor?”“Our products are handmade”
Blue Ocean Thinking
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Industrial Robotics:Introduction and Future
PerspectivesDr. Andrea Paoli
[Illustration by Brucie Rosch]
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Conclusions
What is a robot?What is industrial robotics?
Robotic ArmsMobile Robots
Industry 4.0
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What is a Robot? 1/2 1921: Writer Karel Capek introduced the word
‘robot’ from the Czech word ‘ROBOTA’, meaning ‘drudgery’
A robot is a goal oriented machine that can sense, act and plan
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What is a Robot? 2/2
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Industrial Robotics Re-programmable multi-functional manipulator designed to
move materials, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks, which also acquire information from the environment and move intelligently in response (Robotic Institute of America)
Industrial Automatio
nRobotics
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Mobile Robots 2/2
2016: Arla Foods warehouse
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Robot Economics 1/4
[Barclays Bank – Future Proofing UK Manufacturing, 2015]
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Robot Economics 2/4
[World Robotics 2015 Industrial Robots, IFR]
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Robot Economics 3/4
[World Robotics 2015 Industrial Robots, IFR]
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Robot Economics 4/4
[World Robotics 2015 Industrial Robots, IFR]
What’s going on here?!?
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Industry 4.0
[http://www.engineersjournal.ie]
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Factory of the Future
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[Courtesy WillowGarage]
Do we trust robots?
Basic Safety-Related Functions
Supervision Functions
Intrinsically Safe Robots
Next Generation Predictive Robots
We are here!!
Smar
tnes
s
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Next Generation Safety
Laser Scanner
Controlled 3D cams
Wearable sensorsSmart glasses
Raw dataEye tracking
Body segmentationParts recognitionIntentions detection Human prediction
Robot movements adaptation
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Conclusions Industry 4.0 revolution
Human and Robots work together High productivity and availability
We need to work together More investment Push robotics in less-explored sectors
Robotics of the future Internet of Things Advanced Safety Natural Human/Robot interaction
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Inter-Sector Knowledge Transfer Opportunities
Jeff Nowill, Kuka Robotics
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Demonstration & Pods
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How will robotics change traditional food manufacturing?
Ian Beauchamp, OAL Mark Swainson, University of Lincoln
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• Traditional process / technology base• Labour intensive• Established thinking• Competitive market
How can robotics assist in overcoming these issues?
Potential Impact of Robotics/AutomationTypical food industry issues
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• Product hold-up• Burn-on• Spoilage• Spillages
Margin erosion and increasing disposal costs
Yield ImprovementTypical areas of loss / cost within food processing
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• Manual systems / overrides• Uncontrolled variation / procedure• Ingredient / product handling damage• Preference / interpretation
The ‘human’ factor!
Quality ImprovementTypical areas resulting in poor product quality
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• Small batch size• Ease of reconfiguration• Simplification of hygiene requirements• Reduction in cycle times
Optimised / tailored approach
Requirement for Increased FlexibilityTypical areas to improve flexibility
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• Traditional processes / technologies• Labour intensive operations• Reliance on low skilled contract labour• Staged increase in the minimum wage
Prepared for the future!
Requirement for Reduced Labour CostsTypically within food processing
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• On-line analysis / QA approval• Handling stability / consistency• Downstream synergies – cryogenic cooling• Human / robotic interface
Any questions?
Going ForwardFuture developments within food processing
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The APRIL Vision
Harry Norman, OAL
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• Consumers want more choice• Food deflation• Manufacturers suffering from rising costs• No major advances in productivity• Living Wage• Environmental responsibility
In summary:
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Ingredients for change:
• Technology costs – Moore’s Law, Economies of Scale
• Technology advances – vision, Artificial intelligence
• Connected world – Internet of Things
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• $775 million acquisition late 2012 – Kiva.
• Expected to install 10,000 robots at Amazon warehouses by 2015
• Actual end of 2015 – 30,000 robots!
Other industries continue to invest:Amazon
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Create a Global Centre of Excellence for Robotic Food Manufacturing at the University of Lincoln.
1. Educate the industry.
2. Partner with visionary early adopters.
3. Deliver a disruptive change in manufacturing.
Recipe for food processing automation!
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• Flexible manufacturing• Yield enhancement• Improved product quality / consistency• Smaller factory footprint• Leaner labour force
Genuine competitive advantage
The Icing on the CakeAutomated Processing Robotic Ingredient Loading
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Tours of National Centre for Food Manufacturing