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packaging robotics playbook 2020 EDITION Trends, Case Studies and Get-It-Right Tips

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Page 1: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

packaging robotics playbook

2020EDITION

Trends Case Studies and Get-It-Right Tips

2 Table of contents

3 Leveraging Robotics for Packaging SuccessThe expansion of robotics into new packaging applications and a changing financial case promise to affect operations now and in years to come

9 Perceptive RobotsPackagers are discovering new ways to leverage vision advances and evolving sensor technology for improved quality and greater picking accuracy

15 Agile RobotsEnd-of-arm tooling presents one of the most rapidly changingndashndashand broadeningndashndashareas of robotics

22 Collaborative CapabilitiesDespite limitations on payload cobot use is surging and increasingly a point of productivity differentiation among packagers

31 MobilityWith e-commerce intensifying pressures on warehousing and logistics operations mobile robots are stepping up to the challenge

37 Getting Started with RoboticsWhen implementing robotics its important to follow these tips for assessing needs structuring your project and effectively calculating ROI

43 Bonus SectionMaking Sense of ANSI R1506 and ANSI B1551Do you have a robotic system that does packaging or a packaging machine that includes a robot Heres how to make sense of the standards

Robotics Packaging Playbook

3

Leveraging Robotics for Packaging Success

Page title here4

An increasing number of packagers are facing decisions on whether to automate processes with robotics and with which applications as the capabilities and business case continues to improve

Itrsquos estimated that in the next three years nearly all manufacturers will be operating robots somewhere on the plant floor And nearly two-thirds currently are operating multiple robots working together on the same machine (PMMI Robotics Innovation 2 Implementation 2019)

Goals for this automation vary considerably as the landscape continues to shift

Application ExpansionWithin the food and beverage industry one which is controlled by strict health and safety regulations robots have previously been limited to tertiary and some secondary packaging tasks such as palletizing as they have not met necessary standards to be used in direct contact with food The use case is now changing as suppliers are increasingly developing robots with a high protection class suitable for handling unpacked goods and subsequent wash-down creating new opportunities for the direct and indirect handling of foods

Leveraging Robotics for Packaging Success

5 Leveraging Robotics for Packaging Success

Most recently amid the COVID-19 pandemic robots have come to the fore as a way for manufacturers to more safely keep workers socially distanced on the factory floor and maintain operations Robotic solutions have been key to keeping many high-demand product lines running and often around-the-clock

At the same time as these shifting demands solution capabilities are expanding Improvements in sensor technology data analytics and robotic components have led to robots that are more intelligent and flexible than ever before enabling the wider adoption and expansion of robotics into new applications and industries

A Changing Business CaseFinancial barriers to entry also are shifting Opportunities for packagers to integrate robotic technologies are increasing as systems become more affordable than they have ever been The initial machine cost of robotics has steadily declined installation and integration service costs

are falling programming costs have been reduced and in some cases eliminated entirely and the average time to achieve ROI has plummeted

Over the next few years the business case for investment is projected to continue to become even easier due to anticipated improvements in speed and diversity of robot capabilities programming simplification modular out-of-the-box installation and advances in machine learning

Optimizing OperationsPackagers also are looking to robotics to improve competitive position and productivity Robotic solutions are increasingly key to maintaining and growing manufacturersrsquo profitability as companies continue to find new ways to boost efficiency and cut costs In todayrsquos global economy itrsquos mandatory that manufacturers run leaner and with more efficiency to outpace the competition With the aid of robotics many packagers are finding they

6 Leveraging Robotics for Packaging Success

can increase throughput increase SKUs support shorter product runs and upskill labor Whatrsquos more robots are more consistent and reliable these days with programming advancements that drastically

simplify use As a result many manufacturers are finding new ways to leverage these technologies to improve product consistency provide greater quality assurance and reduce product damage and waste

RobotCobot Applications in Packaging

Primary packaging using robots or in a few instances cobots

Bag handlingBottle handlingCan stackingContainer loadingKit assembly

MultipacksPackage insertsPick and placeQuality inspectionTray loading and unloading

Variety packsCustomized gift packsVision inspectionPolishing finishing

Secondary packaging using robots or in a few instances cobots

Carton loadingCase packingCase sealing

Retail readyTray unloadingVariety packingbundling

Transport packaging applications using robots

PalletizingBuilding efficient pack patternsTransport

FANUC AmericaRochester Hills MI

FANUC is the worldrsquos leading supplier of CNCs robotics and ROBOMACHINEs Together with our team of authorized system integrators we offer automation solutions to help customers solve production challenges maximize productivity and maintain a competitive advantage

Primary Packaging High-speed food-safe robots tolerate sanitation environments and handle primary foods including proteins and ready-to-eat products

Secondary PackagingEasy-to-use robots to pick pack or palletize help customers improve OEE and process consistency and provide changeover flexibility

Experts in Primary and Secondary Packaging Systems Our Authorized System Integrators provide turnkey solutions that help both small and large customers quickly respond to market demands in a wide range of industries and applications

Learn More

FANUC Offers an Extensive Variety of Ro-bots for Picking Packing and PalletizingStandard Delta SCARA and collaborative robots with payload capabilities from 05-2300kg including cleanroom and food-safe models with best-in-class ratings for packaging

Learn More

Trust FANUC for the Worldrsquos Most Reliable Automation Whatever your industry from food amp beverage to cosmetics e-commerce to pharmaceuticals rely on FANUC for a flexible and cost-effective automated solution to meet your production needs

Learn More

Looking for Ways to Stay Competitive in Todayrsquos Global Market Lets TalkWhether yoursquore considering a new automated solution or updates to an existing process our team is here to help you meet your production goals to improve efficiency and profitability

Learn More

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 2: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

2 Table of contents

3 Leveraging Robotics for Packaging SuccessThe expansion of robotics into new packaging applications and a changing financial case promise to affect operations now and in years to come

9 Perceptive RobotsPackagers are discovering new ways to leverage vision advances and evolving sensor technology for improved quality and greater picking accuracy

15 Agile RobotsEnd-of-arm tooling presents one of the most rapidly changingndashndashand broadeningndashndashareas of robotics

22 Collaborative CapabilitiesDespite limitations on payload cobot use is surging and increasingly a point of productivity differentiation among packagers

31 MobilityWith e-commerce intensifying pressures on warehousing and logistics operations mobile robots are stepping up to the challenge

37 Getting Started with RoboticsWhen implementing robotics its important to follow these tips for assessing needs structuring your project and effectively calculating ROI

43 Bonus SectionMaking Sense of ANSI R1506 and ANSI B1551Do you have a robotic system that does packaging or a packaging machine that includes a robot Heres how to make sense of the standards

Robotics Packaging Playbook

3

Leveraging Robotics for Packaging Success

Page title here4

An increasing number of packagers are facing decisions on whether to automate processes with robotics and with which applications as the capabilities and business case continues to improve

Itrsquos estimated that in the next three years nearly all manufacturers will be operating robots somewhere on the plant floor And nearly two-thirds currently are operating multiple robots working together on the same machine (PMMI Robotics Innovation 2 Implementation 2019)

Goals for this automation vary considerably as the landscape continues to shift

Application ExpansionWithin the food and beverage industry one which is controlled by strict health and safety regulations robots have previously been limited to tertiary and some secondary packaging tasks such as palletizing as they have not met necessary standards to be used in direct contact with food The use case is now changing as suppliers are increasingly developing robots with a high protection class suitable for handling unpacked goods and subsequent wash-down creating new opportunities for the direct and indirect handling of foods

Leveraging Robotics for Packaging Success

5 Leveraging Robotics for Packaging Success

Most recently amid the COVID-19 pandemic robots have come to the fore as a way for manufacturers to more safely keep workers socially distanced on the factory floor and maintain operations Robotic solutions have been key to keeping many high-demand product lines running and often around-the-clock

At the same time as these shifting demands solution capabilities are expanding Improvements in sensor technology data analytics and robotic components have led to robots that are more intelligent and flexible than ever before enabling the wider adoption and expansion of robotics into new applications and industries

A Changing Business CaseFinancial barriers to entry also are shifting Opportunities for packagers to integrate robotic technologies are increasing as systems become more affordable than they have ever been The initial machine cost of robotics has steadily declined installation and integration service costs

are falling programming costs have been reduced and in some cases eliminated entirely and the average time to achieve ROI has plummeted

Over the next few years the business case for investment is projected to continue to become even easier due to anticipated improvements in speed and diversity of robot capabilities programming simplification modular out-of-the-box installation and advances in machine learning

Optimizing OperationsPackagers also are looking to robotics to improve competitive position and productivity Robotic solutions are increasingly key to maintaining and growing manufacturersrsquo profitability as companies continue to find new ways to boost efficiency and cut costs In todayrsquos global economy itrsquos mandatory that manufacturers run leaner and with more efficiency to outpace the competition With the aid of robotics many packagers are finding they

6 Leveraging Robotics for Packaging Success

can increase throughput increase SKUs support shorter product runs and upskill labor Whatrsquos more robots are more consistent and reliable these days with programming advancements that drastically

simplify use As a result many manufacturers are finding new ways to leverage these technologies to improve product consistency provide greater quality assurance and reduce product damage and waste

RobotCobot Applications in Packaging

Primary packaging using robots or in a few instances cobots

Bag handlingBottle handlingCan stackingContainer loadingKit assembly

MultipacksPackage insertsPick and placeQuality inspectionTray loading and unloading

Variety packsCustomized gift packsVision inspectionPolishing finishing

Secondary packaging using robots or in a few instances cobots

Carton loadingCase packingCase sealing

Retail readyTray unloadingVariety packingbundling

Transport packaging applications using robots

PalletizingBuilding efficient pack patternsTransport

FANUC AmericaRochester Hills MI

FANUC is the worldrsquos leading supplier of CNCs robotics and ROBOMACHINEs Together with our team of authorized system integrators we offer automation solutions to help customers solve production challenges maximize productivity and maintain a competitive advantage

Primary Packaging High-speed food-safe robots tolerate sanitation environments and handle primary foods including proteins and ready-to-eat products

Secondary PackagingEasy-to-use robots to pick pack or palletize help customers improve OEE and process consistency and provide changeover flexibility

Experts in Primary and Secondary Packaging Systems Our Authorized System Integrators provide turnkey solutions that help both small and large customers quickly respond to market demands in a wide range of industries and applications

Learn More

FANUC Offers an Extensive Variety of Ro-bots for Picking Packing and PalletizingStandard Delta SCARA and collaborative robots with payload capabilities from 05-2300kg including cleanroom and food-safe models with best-in-class ratings for packaging

Learn More

Trust FANUC for the Worldrsquos Most Reliable Automation Whatever your industry from food amp beverage to cosmetics e-commerce to pharmaceuticals rely on FANUC for a flexible and cost-effective automated solution to meet your production needs

Learn More

Looking for Ways to Stay Competitive in Todayrsquos Global Market Lets TalkWhether yoursquore considering a new automated solution or updates to an existing process our team is here to help you meet your production goals to improve efficiency and profitability

Learn More

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 3: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robotics Packaging Playbook

3

Leveraging Robotics for Packaging Success

Page title here4

An increasing number of packagers are facing decisions on whether to automate processes with robotics and with which applications as the capabilities and business case continues to improve

Itrsquos estimated that in the next three years nearly all manufacturers will be operating robots somewhere on the plant floor And nearly two-thirds currently are operating multiple robots working together on the same machine (PMMI Robotics Innovation 2 Implementation 2019)

Goals for this automation vary considerably as the landscape continues to shift

Application ExpansionWithin the food and beverage industry one which is controlled by strict health and safety regulations robots have previously been limited to tertiary and some secondary packaging tasks such as palletizing as they have not met necessary standards to be used in direct contact with food The use case is now changing as suppliers are increasingly developing robots with a high protection class suitable for handling unpacked goods and subsequent wash-down creating new opportunities for the direct and indirect handling of foods

Leveraging Robotics for Packaging Success

5 Leveraging Robotics for Packaging Success

Most recently amid the COVID-19 pandemic robots have come to the fore as a way for manufacturers to more safely keep workers socially distanced on the factory floor and maintain operations Robotic solutions have been key to keeping many high-demand product lines running and often around-the-clock

At the same time as these shifting demands solution capabilities are expanding Improvements in sensor technology data analytics and robotic components have led to robots that are more intelligent and flexible than ever before enabling the wider adoption and expansion of robotics into new applications and industries

A Changing Business CaseFinancial barriers to entry also are shifting Opportunities for packagers to integrate robotic technologies are increasing as systems become more affordable than they have ever been The initial machine cost of robotics has steadily declined installation and integration service costs

are falling programming costs have been reduced and in some cases eliminated entirely and the average time to achieve ROI has plummeted

Over the next few years the business case for investment is projected to continue to become even easier due to anticipated improvements in speed and diversity of robot capabilities programming simplification modular out-of-the-box installation and advances in machine learning

Optimizing OperationsPackagers also are looking to robotics to improve competitive position and productivity Robotic solutions are increasingly key to maintaining and growing manufacturersrsquo profitability as companies continue to find new ways to boost efficiency and cut costs In todayrsquos global economy itrsquos mandatory that manufacturers run leaner and with more efficiency to outpace the competition With the aid of robotics many packagers are finding they

6 Leveraging Robotics for Packaging Success

can increase throughput increase SKUs support shorter product runs and upskill labor Whatrsquos more robots are more consistent and reliable these days with programming advancements that drastically

simplify use As a result many manufacturers are finding new ways to leverage these technologies to improve product consistency provide greater quality assurance and reduce product damage and waste

RobotCobot Applications in Packaging

Primary packaging using robots or in a few instances cobots

Bag handlingBottle handlingCan stackingContainer loadingKit assembly

MultipacksPackage insertsPick and placeQuality inspectionTray loading and unloading

Variety packsCustomized gift packsVision inspectionPolishing finishing

Secondary packaging using robots or in a few instances cobots

Carton loadingCase packingCase sealing

Retail readyTray unloadingVariety packingbundling

Transport packaging applications using robots

PalletizingBuilding efficient pack patternsTransport

FANUC AmericaRochester Hills MI

FANUC is the worldrsquos leading supplier of CNCs robotics and ROBOMACHINEs Together with our team of authorized system integrators we offer automation solutions to help customers solve production challenges maximize productivity and maintain a competitive advantage

Primary Packaging High-speed food-safe robots tolerate sanitation environments and handle primary foods including proteins and ready-to-eat products

Secondary PackagingEasy-to-use robots to pick pack or palletize help customers improve OEE and process consistency and provide changeover flexibility

Experts in Primary and Secondary Packaging Systems Our Authorized System Integrators provide turnkey solutions that help both small and large customers quickly respond to market demands in a wide range of industries and applications

Learn More

FANUC Offers an Extensive Variety of Ro-bots for Picking Packing and PalletizingStandard Delta SCARA and collaborative robots with payload capabilities from 05-2300kg including cleanroom and food-safe models with best-in-class ratings for packaging

Learn More

Trust FANUC for the Worldrsquos Most Reliable Automation Whatever your industry from food amp beverage to cosmetics e-commerce to pharmaceuticals rely on FANUC for a flexible and cost-effective automated solution to meet your production needs

Learn More

Looking for Ways to Stay Competitive in Todayrsquos Global Market Lets TalkWhether yoursquore considering a new automated solution or updates to an existing process our team is here to help you meet your production goals to improve efficiency and profitability

Learn More

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 4: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Page title here4

An increasing number of packagers are facing decisions on whether to automate processes with robotics and with which applications as the capabilities and business case continues to improve

Itrsquos estimated that in the next three years nearly all manufacturers will be operating robots somewhere on the plant floor And nearly two-thirds currently are operating multiple robots working together on the same machine (PMMI Robotics Innovation 2 Implementation 2019)

Goals for this automation vary considerably as the landscape continues to shift

Application ExpansionWithin the food and beverage industry one which is controlled by strict health and safety regulations robots have previously been limited to tertiary and some secondary packaging tasks such as palletizing as they have not met necessary standards to be used in direct contact with food The use case is now changing as suppliers are increasingly developing robots with a high protection class suitable for handling unpacked goods and subsequent wash-down creating new opportunities for the direct and indirect handling of foods

Leveraging Robotics for Packaging Success

5 Leveraging Robotics for Packaging Success

Most recently amid the COVID-19 pandemic robots have come to the fore as a way for manufacturers to more safely keep workers socially distanced on the factory floor and maintain operations Robotic solutions have been key to keeping many high-demand product lines running and often around-the-clock

At the same time as these shifting demands solution capabilities are expanding Improvements in sensor technology data analytics and robotic components have led to robots that are more intelligent and flexible than ever before enabling the wider adoption and expansion of robotics into new applications and industries

A Changing Business CaseFinancial barriers to entry also are shifting Opportunities for packagers to integrate robotic technologies are increasing as systems become more affordable than they have ever been The initial machine cost of robotics has steadily declined installation and integration service costs

are falling programming costs have been reduced and in some cases eliminated entirely and the average time to achieve ROI has plummeted

Over the next few years the business case for investment is projected to continue to become even easier due to anticipated improvements in speed and diversity of robot capabilities programming simplification modular out-of-the-box installation and advances in machine learning

Optimizing OperationsPackagers also are looking to robotics to improve competitive position and productivity Robotic solutions are increasingly key to maintaining and growing manufacturersrsquo profitability as companies continue to find new ways to boost efficiency and cut costs In todayrsquos global economy itrsquos mandatory that manufacturers run leaner and with more efficiency to outpace the competition With the aid of robotics many packagers are finding they

6 Leveraging Robotics for Packaging Success

can increase throughput increase SKUs support shorter product runs and upskill labor Whatrsquos more robots are more consistent and reliable these days with programming advancements that drastically

simplify use As a result many manufacturers are finding new ways to leverage these technologies to improve product consistency provide greater quality assurance and reduce product damage and waste

RobotCobot Applications in Packaging

Primary packaging using robots or in a few instances cobots

Bag handlingBottle handlingCan stackingContainer loadingKit assembly

MultipacksPackage insertsPick and placeQuality inspectionTray loading and unloading

Variety packsCustomized gift packsVision inspectionPolishing finishing

Secondary packaging using robots or in a few instances cobots

Carton loadingCase packingCase sealing

Retail readyTray unloadingVariety packingbundling

Transport packaging applications using robots

PalletizingBuilding efficient pack patternsTransport

FANUC AmericaRochester Hills MI

FANUC is the worldrsquos leading supplier of CNCs robotics and ROBOMACHINEs Together with our team of authorized system integrators we offer automation solutions to help customers solve production challenges maximize productivity and maintain a competitive advantage

Primary Packaging High-speed food-safe robots tolerate sanitation environments and handle primary foods including proteins and ready-to-eat products

Secondary PackagingEasy-to-use robots to pick pack or palletize help customers improve OEE and process consistency and provide changeover flexibility

Experts in Primary and Secondary Packaging Systems Our Authorized System Integrators provide turnkey solutions that help both small and large customers quickly respond to market demands in a wide range of industries and applications

Learn More

FANUC Offers an Extensive Variety of Ro-bots for Picking Packing and PalletizingStandard Delta SCARA and collaborative robots with payload capabilities from 05-2300kg including cleanroom and food-safe models with best-in-class ratings for packaging

Learn More

Trust FANUC for the Worldrsquos Most Reliable Automation Whatever your industry from food amp beverage to cosmetics e-commerce to pharmaceuticals rely on FANUC for a flexible and cost-effective automated solution to meet your production needs

Learn More

Looking for Ways to Stay Competitive in Todayrsquos Global Market Lets TalkWhether yoursquore considering a new automated solution or updates to an existing process our team is here to help you meet your production goals to improve efficiency and profitability

Learn More

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 5: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

5 Leveraging Robotics for Packaging Success

Most recently amid the COVID-19 pandemic robots have come to the fore as a way for manufacturers to more safely keep workers socially distanced on the factory floor and maintain operations Robotic solutions have been key to keeping many high-demand product lines running and often around-the-clock

At the same time as these shifting demands solution capabilities are expanding Improvements in sensor technology data analytics and robotic components have led to robots that are more intelligent and flexible than ever before enabling the wider adoption and expansion of robotics into new applications and industries

A Changing Business CaseFinancial barriers to entry also are shifting Opportunities for packagers to integrate robotic technologies are increasing as systems become more affordable than they have ever been The initial machine cost of robotics has steadily declined installation and integration service costs

are falling programming costs have been reduced and in some cases eliminated entirely and the average time to achieve ROI has plummeted

Over the next few years the business case for investment is projected to continue to become even easier due to anticipated improvements in speed and diversity of robot capabilities programming simplification modular out-of-the-box installation and advances in machine learning

Optimizing OperationsPackagers also are looking to robotics to improve competitive position and productivity Robotic solutions are increasingly key to maintaining and growing manufacturersrsquo profitability as companies continue to find new ways to boost efficiency and cut costs In todayrsquos global economy itrsquos mandatory that manufacturers run leaner and with more efficiency to outpace the competition With the aid of robotics many packagers are finding they

6 Leveraging Robotics for Packaging Success

can increase throughput increase SKUs support shorter product runs and upskill labor Whatrsquos more robots are more consistent and reliable these days with programming advancements that drastically

simplify use As a result many manufacturers are finding new ways to leverage these technologies to improve product consistency provide greater quality assurance and reduce product damage and waste

RobotCobot Applications in Packaging

Primary packaging using robots or in a few instances cobots

Bag handlingBottle handlingCan stackingContainer loadingKit assembly

MultipacksPackage insertsPick and placeQuality inspectionTray loading and unloading

Variety packsCustomized gift packsVision inspectionPolishing finishing

Secondary packaging using robots or in a few instances cobots

Carton loadingCase packingCase sealing

Retail readyTray unloadingVariety packingbundling

Transport packaging applications using robots

PalletizingBuilding efficient pack patternsTransport

FANUC AmericaRochester Hills MI

FANUC is the worldrsquos leading supplier of CNCs robotics and ROBOMACHINEs Together with our team of authorized system integrators we offer automation solutions to help customers solve production challenges maximize productivity and maintain a competitive advantage

Primary Packaging High-speed food-safe robots tolerate sanitation environments and handle primary foods including proteins and ready-to-eat products

Secondary PackagingEasy-to-use robots to pick pack or palletize help customers improve OEE and process consistency and provide changeover flexibility

Experts in Primary and Secondary Packaging Systems Our Authorized System Integrators provide turnkey solutions that help both small and large customers quickly respond to market demands in a wide range of industries and applications

Learn More

FANUC Offers an Extensive Variety of Ro-bots for Picking Packing and PalletizingStandard Delta SCARA and collaborative robots with payload capabilities from 05-2300kg including cleanroom and food-safe models with best-in-class ratings for packaging

Learn More

Trust FANUC for the Worldrsquos Most Reliable Automation Whatever your industry from food amp beverage to cosmetics e-commerce to pharmaceuticals rely on FANUC for a flexible and cost-effective automated solution to meet your production needs

Learn More

Looking for Ways to Stay Competitive in Todayrsquos Global Market Lets TalkWhether yoursquore considering a new automated solution or updates to an existing process our team is here to help you meet your production goals to improve efficiency and profitability

Learn More

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 6: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

6 Leveraging Robotics for Packaging Success

can increase throughput increase SKUs support shorter product runs and upskill labor Whatrsquos more robots are more consistent and reliable these days with programming advancements that drastically

simplify use As a result many manufacturers are finding new ways to leverage these technologies to improve product consistency provide greater quality assurance and reduce product damage and waste

RobotCobot Applications in Packaging

Primary packaging using robots or in a few instances cobots

Bag handlingBottle handlingCan stackingContainer loadingKit assembly

MultipacksPackage insertsPick and placeQuality inspectionTray loading and unloading

Variety packsCustomized gift packsVision inspectionPolishing finishing

Secondary packaging using robots or in a few instances cobots

Carton loadingCase packingCase sealing

Retail readyTray unloadingVariety packingbundling

Transport packaging applications using robots

PalletizingBuilding efficient pack patternsTransport

FANUC AmericaRochester Hills MI

FANUC is the worldrsquos leading supplier of CNCs robotics and ROBOMACHINEs Together with our team of authorized system integrators we offer automation solutions to help customers solve production challenges maximize productivity and maintain a competitive advantage

Primary Packaging High-speed food-safe robots tolerate sanitation environments and handle primary foods including proteins and ready-to-eat products

Secondary PackagingEasy-to-use robots to pick pack or palletize help customers improve OEE and process consistency and provide changeover flexibility

Experts in Primary and Secondary Packaging Systems Our Authorized System Integrators provide turnkey solutions that help both small and large customers quickly respond to market demands in a wide range of industries and applications

Learn More

FANUC Offers an Extensive Variety of Ro-bots for Picking Packing and PalletizingStandard Delta SCARA and collaborative robots with payload capabilities from 05-2300kg including cleanroom and food-safe models with best-in-class ratings for packaging

Learn More

Trust FANUC for the Worldrsquos Most Reliable Automation Whatever your industry from food amp beverage to cosmetics e-commerce to pharmaceuticals rely on FANUC for a flexible and cost-effective automated solution to meet your production needs

Learn More

Looking for Ways to Stay Competitive in Todayrsquos Global Market Lets TalkWhether yoursquore considering a new automated solution or updates to an existing process our team is here to help you meet your production goals to improve efficiency and profitability

Learn More

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 7: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

FANUC AmericaRochester Hills MI

FANUC is the worldrsquos leading supplier of CNCs robotics and ROBOMACHINEs Together with our team of authorized system integrators we offer automation solutions to help customers solve production challenges maximize productivity and maintain a competitive advantage

Primary Packaging High-speed food-safe robots tolerate sanitation environments and handle primary foods including proteins and ready-to-eat products

Secondary PackagingEasy-to-use robots to pick pack or palletize help customers improve OEE and process consistency and provide changeover flexibility

Experts in Primary and Secondary Packaging Systems Our Authorized System Integrators provide turnkey solutions that help both small and large customers quickly respond to market demands in a wide range of industries and applications

Learn More

FANUC Offers an Extensive Variety of Ro-bots for Picking Packing and PalletizingStandard Delta SCARA and collaborative robots with payload capabilities from 05-2300kg including cleanroom and food-safe models with best-in-class ratings for packaging

Learn More

Trust FANUC for the Worldrsquos Most Reliable Automation Whatever your industry from food amp beverage to cosmetics e-commerce to pharmaceuticals rely on FANUC for a flexible and cost-effective automated solution to meet your production needs

Learn More

Looking for Ways to Stay Competitive in Todayrsquos Global Market Lets TalkWhether yoursquore considering a new automated solution or updates to an existing process our team is here to help you meet your production goals to improve efficiency and profitability

Learn More

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 8: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

8 Leveraging Robotics for Packaging Success

For packagers seeking to optimize their operations with robotics four trends are particularly important to watch

bull Perceptivenessbull Agilitybull Collaborative capabilitiesbull Mobility

Also important when getting started with robotics is best positioning your organization to achieve its goals Success typically depends on careful assessment of automation needs around the project aligning the full team of stakeholders around staggered goals andor gradual increases in project scope understanding key selection criteria based on current needs and robotic capabilities and recognizing the many direct and indirect factors that can influence total cost of ownership

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 9: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robotics Packaging Playbook

9

Perceptive Robots

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 10: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

10 Perceptive Robots

Advances in perceptive robots offer packagers one of the biggest opportunities for improving

productivity Vision-capable robots are proficient at removing faulty products from the line and inspecting label accuracy Improvements in managing visual data have allowed these systems to become more accurate when picking objects safer when operating around humans and more consistent in their ability to reject faulty products

Current LandscapeSeveral trends in perceptive robotics are important to note

Wider adoption and affordability of 2D solutions Many packaging applications make use of 2D machine vision where grayscale or color imaging creates a two-dimensional map that allows for easy detection of anomalies or variation in part contrast A 2D vision system allows robots to determine object movement shape and size In these applications objects being

scanned must be on a flat surface (X Y on a single plane) and be of a consistent size and shape

As this type of vision increasingly becomes cheaper and faster its use in packaging continues to grow particularly in functions associated with inspection barcode reading surface marking detection and basic positional verification

Broader applications made possible with 3D vision Three-dimensional vision gives insight into product depth and height It is therefore required for more random situations where items are located haphazardly or stacked in a bin with varying orientation Use of 3D vision has forged the way for taking on packaging processes once thought ill-suited to robotics such as working with complex shapes and handling products with reflective properties

For those working with flexible packaging probably most notable has been advancements in the use

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 11: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

11

of 3D vision to provide greater accuracy when locating the position and edges of objects These capabilities have now opened the door to robotic applications that involve handling of bags

Greater tactile sensitivity and production intelligence Another key area opening new applications is advances in tactile sensors The development of tactile sensors that are capable of gauging pressure and detecting contact has allowed todayrsquos perceptive robots to safely disengage when coming into contact with a person or fixed object Sensors also enable the manipulation of delicate objects without breaking them Technology has advanced to the point that robotics can successfully manage even those applications requiring picking very fragile or randomly oriented finished products in need of correct placement to be packed (see case study on page 12)

In addition vision and tactile sensor advancements are creating several new data collection points for

manufacturing operations giving brand owners the opportunity to analyze and optimize production processes from new angles Packagers are learning how to utilize integrated sensor technology as a way to more directly and intelligently control production processes on-the-fly Todayrsquos sensors can capture more detail and transfer more data to a computer for better analysis

Because of these capabilities perceptive robots are increasingly more accurate more flexible and able to drive profitability in a wider range of applications

What Packagers Should WatchRobotics suppliers are continuously improving vision clarity speed and accuracy At present many robotic vision solutions operate as part of 247 lines where end-of-arm tooling supports random unsorted bin picking Another popular use for vision-capable robots among packagers is verifying label accuracy where robots are particularly proficient at identifying faulty products that need to be removed from the line

Perceptive Robots

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 12: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

12 Perceptive Robots

Tip Keep up With Sensor Trends

Perception is changing in many ways thanks to advances in sensors

bull Enhanced vision sensors capable of multiple images are improving product inspection enabling dynamic picking and increasing spatial awareness

bull Integrated thermal imaging is being used to supplement vision sensor capabilities in adhesive inspection for case sealing

bull Tactile sensors such as capacitive skins that react to contact and give a sense of touch are opening new capabilities for delicate picking

Changes in sensor capabilities continue to open opportunities for new packaging applications So yoursquoll want to stay current on sensor developments

On the horizon expect robots to accomplish tasks that require even greater levels of selectivity Widespread use of 3D and color cameras will target a range of applications including de-palletizing bin picking pick and place assembly packing and quality control to achieve new levels of efficiency and consistency in product output

In addition as advances in AI vision and deep learning continue to converge packagers can expect new applications involving artificial intelligence and deep learning from robots Combining artificial intelligence with machine vision systems is supporting significant developments in quality control providing the eyes and brain behind the robot to enable it to identify faulty products and remove them from the production process As artificial intelligence moves out of the research phase itrsquos expected that one day it will be common for robots to use sensors and vision as a means to gather statistical data that can then be translated to an end-of-arm tool for corrective decision making

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 13: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

ColumbiaOkura LLCVancouver WA

ColumbiaOkura LLC designs integrates and com-missionsend-of-line robotic palletizing solutions formost major industries For over 20 years Colum-biaOkura LLC has been a leading provider of robotic palletizing systems by delivering custom engineered solutions to meet demanding customer require-ments Headquartered in Vancouver Washington ColumbiaOkura LLC is a joint venture of material handling leaders Columbia Machine Inc and Okura Yusoki Co Ltd

WHO WE AREWe are company with dedicated and passionate professionals applying expert knowledge and the right tools to solve customerrsquos end of line production challenges

WHAT WE DOWe are a value based end of line palletizing solution that meets or exceeds customer requirements Dura-ble Reliable amp Performance Guarantee

Get Started with a CobotCost-effective safe and flexible collaborative robots or cobots are making automation easier than ever even for small and mid-sized companies

Watch Video

Our bagging Line Solution with an Automatic Palletizing SystemLooking for a complete bagging line solution Watch this video to see how we can help improve your production line

Watch Video

Our rugged robotic palletizers can handle your toughest jobsLet us integrate your middle to end of line solutions to keep your facility safe and efficient

Watch Video

The people and palletizing systemsOur talented and dedicated employees are passionate about designing integrating commissioning and supporting robotic palletizing systems

Watch Video

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 14: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

14 Perceptive Robots

Case Study Perceptive RobotsVision Capabilities Allow Confectioner to Remove Faulty Variants of Fragile Product at 500 PacksMin

The project One confectioner has found significant

productivity advantages from automating its presorting

and packaging process for its chocolate praline candies

A key challenge was accurate inspection of a challenging

product and the need for accurate picking with keen

spatial awareness at 500 packsmin speeds

The process The confectioner implemented a system

equipped with six sub-machines each one with its own

robot At the first sub-machine plastic trays holding

assorted chocolates are picked with a robot from a

magazine and are placed onto a single-axis rail-based

transport system This station is followed by three sub-

machines with integrated four-axis pick-and-place

robots that fill the trays with product Each sub-machine

is supplied with product from three separate infeeds

A reflected-light scanner detects the position of

the products and also assesses quality Only perfect

chocolates are picked up by the robots and placed into

the plastic trays To handle the chocolates without

damaging them the robots use soft half-shell-shaped

grippers adapted to the shape of the hemispherical

products that use vacuum to gently transfer the

chocolates from the belt to the plastic trays

In the next sub-machine two two-axis robots

place the fully loaded trays into pre-erected double-

walled boxes and depending on which of 20 formats

is desired the robots place candy pads on the trays to

protect the products

The result Perceptive robots aid quality control in a

challenging picking and placing environment while

meeting high-speed demands

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 15: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robotics Packaging Playbook

15

Agile Robots

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

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Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

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First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

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Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 16: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robots have used multiple types of end-of-arm tooling and grippers for years but the desire for

more manual dexterity among packagers has become more urgent in recent years for several reasons

bull Desire for rapid fulfillment of e-commerce ordersbull Increasing speedsbull Demands from those manufacturers producing

fragile products or products that are differently sized or textured to achieve efficiencies seen with other applications

Attaining necessary levels of agility can be challenging in that solutions arenrsquot one-size-fits-all Robotic arm technologies must be designed around the size shape weight center of gravity and surface hardness of the items they handle They also need to be able to accommodate the precision required of the application and cycle times Because of this solutions tend to be very customized

Current LandscapeModern grippers have evolved to support the actuation of a wide range of products from miniature to enormous robust to delicate Technologies are even improving for better manipulating products with inconsistent size shape and texture as is often needed with handling food products

Several trends in robotic agility are important to note

Accuracy Recent advancements have seen robots improve accuracy when monitoring force orientation pressure temperature acceleration and proximity These developments are having a dramatic impact on the variety of packaging applications for which robots can be used At the same time advances in arm technologies have facilitated better handling and grasping operations at high speed while still having the dexterity and flexibility of movement so as not to damage product

16 Agile Robots

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 17: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

17 Agile Robots

being moved These innovations and smarter sensor feedback have broadened pick-and-place use with even very fragile products

Dexterity Also notable are changes in dexterity Advancements in materials used in arm technologies are now making possible new levels of reliability and flexibility in movement The incorporation of polymers that can expand and apply the proper amount of pressure to specific objects allows new robots to grasp and lift things that didnrsquot used to be possible Force sensors have added further intelligence of movement allowing arms to operate more safely around humans In addition precision improvements are creating new application opportunities in even small and delicate environments

Ease of cleaning Many robotics suppliers also have been focusing efforts on meeting hygienic design standards to support direct contact with food and pharma From ensuring contact points resist corrosion to engineering systems that withstand high-pressure wash-down environments todayrsquos robots are increasingly able to support high levels of hygienic standards

What Packagers Should WatchAdvances are moving toward lighter arm technologies with faster response times and expanded data storage capacity for greater product

TIP Donrsquot expect grippers to be one-size-fits-all or even most

Yoursquoll want to work with a trusted supplier to find a gripper most suited for your line based on desired level of

bull Flexibilitymdashvariation of different sized or shaped products

bull Cycle timesmdashline speed need

bull Hygienemdashease and ability to support cleanability and safe handling

bull Controlled pressuremdashfeedback needed to eliminate damage to fragile product

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 18: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

18 Agile Robots

recognition New materials in the shift from aluminum to plastics offer end users the prospect of less weight without sacrificing strength

Grippers also are improving Soft grippers allow robots to handle increasingly diverse soft or hard parts by making use of flexible material and fluid or air pressure Other innovative grippers use electro-adhesion or a multitude of sensors for gripper guidance Such advances allow for far greater versatility in use

In addition robots will have increased mobility in the coming years being able to move along the line and be recommissioned for another task Many suppliers have been pursuing hybrid tooling combining multiple gripper technologies in a single end-of-arm tool These advances combined with AI are paving the way for automatic tool changers and built-in adjustability

With these setups a robot outfitted with multiple arms and different gripper configurations would allow AI to choose which arm to use for a certain task significantly increasing application capabilities and speed

Intelligence continues to change the landscape in other ways as well Robotsrsquo speed and accuracy in recognizing and picking a variety of unlike objects from a bin are expected to greatly improve

Also information collected by end-of-arm tools provides a wealth of application data for analysis With the aid of artificial intelligence making sense of the data end-of-arm tools are ldquolearningrdquo to navigate semi-structured environments to continue to advance flexibility and accuracy In addition machine learning is allowing robots to become independently adaptive to unfamiliar objects and tasks

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 19: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Syntegon Packaging Technology

New Richmond WI

Syntegon formerly Bosch Packaging is a complete automation solution provider for primary secondary packaging applications The company has decades of application experience designing amp manufacturing proprietary robotic solutions as well as collaborating with FANUC as a licensed integrator

ApplicationsPick-and-place robots to handle wrapped or unwrapped product for feed placing or top loading applications

Market applicationsSuitable for food and non-food products including bars bakery confectionery fresh amp frozen foods and medical devices

High-Speed versatile robot for feed placing or top loading The Paloma D3 robot can pick and place products into cartons cases thermoforms flow wrappers or cartoning machines

Watch Video

Syntegon robotic capabilitiesFrom single robotic arms to multi-machine picking lines we have decades of robotic experience for all levels of automation

Watch Video

Integrated robotic automation As a licensed FANUC integrator we are able to integrate robotic arms with new or existing machines for increased automation

Watch Video

Automated system for kitting with robotic cartoning Fully automated system for packaging medical kits using our Presto D3 robot to collate and load product into cartons

Watch Video

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 20: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

20 Agile Robots

Case Study Agile RobotsVacuum Grippers Delicately Orient Fill and Pack Croissants

The project A baked goods manufacturer required

a fully automated system that could efficiently inject

fillings into its prebaked croissants and package

them without damaging product integrity The

resulting automated system consists of four sub-

machines or modules outfitted with three four-axis

pick-and-place robots with vision two two-axis

robots and single-axis rail-based transport robots

The process The packaging line is fed by a conveyor

that carries baked croissants from the oven to the

first module for pre-grouping Here a 2D image

recognition system checks the position of the

products on the conveyor and transmits the data

to the robots at the next station Controlled by two

servomotors the pick-and-place robots can execute

any movements within a 2D working field Since the

croissants are delicate and vary in height density

and consistency the robots must handle them

carefully This handling is performed by four grippers

and flexible damping on the robot tools which do not

dent or damage the soft and still-warm products

The task of the picker arms is to grasp the

croissants one at a time with control done by air

pressure orient the pastries and then place the

pastries into 12 evenly spaced ldquopucksrdquo or holders

The transport robot then brings the croissants to

the injection station During filling a robot with 12

vacuum gripper heads positions the croissants while

a component with 12 injection needles punctures

continued on next page

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 21: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

21 Agile Robots

the croissants filling them with jam chocolate or

vanilla cream The needles are adjustable in height

depending on how deep they need to inject the filling

into the baked goods which gives the baked goods

company the flexibility to run different products on

the line

Once the croissants have been filled they travel

out of the injection station after which another robot

picks up the row of 12 and places it back onto the

conveyor belt Meanwhile the now-empty holder

flips over and rotates back to the beginning of the

system ready to be loaded with more product

The result Using this automation solution the

baked goods company can fill and package 160

croissantsmin and the system is flexible enough to

enable similar filling of different baked goods so the

company can expand its range of pastries as needed

Case Study Agile Robots Continued

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 22: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robotics Packaging Playbook

22

Collaborative Capabilities

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 23: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

23

Collaborative robots or ldquocobotsrdquo are robots designed to work safely in conjunction with

human labor Force speed and movement paths are monitored and controlled to minimize risk and sensors embedded in the systems detect human presence to trigger a safety mode

Because cobots operate in this controlled fashion typically at low speeds they donrsquot require the same segregated workcells as traditional industrial robots Without the need for the same protective fencing and automation integration considerations as industrial robots cobots tend to be considerably less expensive

Cobots are often well-suited to carry out dull repetitive dirty or dangerous handling tasks where human intervention is less desired Even though cobots typically are slower and less powerful than conventional industrial robots they are deemed highly flexible meaning they can be an attractive solution in applications vulnerable to change

Part of this flexibility is because cobots can be very easy to teach Many cobots come with software that allows a user to reprogram the technology for use at different task points This means a cobot can be moved to a new job and perform a new function rather quickly frequently in under an hour

Such qualities make cobots a natural choice for tasks such as machining and assembly materials handling dispensing product inspection packing and palletizing

Current LandscapeThanks to improvements in sensor and data processing technology the cobots of today can safely work alongside humans without the need for a guarded cell Programming has become increasingly simplified with some robots capable of being programmed through demonstration alone Also machine learning is increasingly allowing robots to become independently adaptive to unfamiliar objects and tasks

Collaborative Capabilities

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 24: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

24

Several trends in cobots are important to note

A continued boom given low barrier of entry for many packagers Cobots are some of the newest tools that are more available to companies of all sizes they are compact moveable and affordable Cobots typically lower the cost of a workstation on lines with shorter runs or unusual package configurations As such cobots are predicted to see some of the most significant growth in robotics over the next five years particularly with slow-speed niche applications Cobots accounted for about 3 of all robot sales in NA in 2017 This number is expected to jump to 34 in 2025 (Source PMMI Robotics Innovation 2 Implementation 2019)

Changing approaches to safety The cobot products and devices that are currently on the market have some limitations in meeting all of the requirements expected of safe and unhindered human-robot collaboration With no safety guarding most cobots are limited to slow movement have lighter payload are best suited to low-volume applications and typically function in small footprints often mounted to a floor wall or ceiling

The development of new sensor and robot technologies along with intelligent control systems is increasingly improving safety and widening

Collaborative Capabilities

Tip Donrsquot Just Introduce a Cobot Into Existing Workflow

Examine your processes and production schedules for opportunities to be more productive using automation For example can a cobot perform overnight to add another shift or could the cobot advance production steps overnight so that next tasks are waiting to be completed when workers arrive each morning

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 25: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

JLS AutomationYork PA

JLS offers both primary and secondary robotic packaging systems for high sanitary food packaging environments Sanitary design is standard - our machines are made to get wet Our systems integration group can design test and install complete lines from start to finish

Product ApplicationsPick-and-place robotics robotic case packing Robotic cartoning and other applications

Vertical Market ApplicationsFocused on food including meat amp poultry bakery and snacks confectionary frozen foods prepared foods and ice cream treats

New Articulating Gripper EOAT Allows Flat to Vertical Pack in SecondsVersatile loading from flat to vertical pack Allows high-speed loading of retail SUPs and high-payload food service bags No tool or vision change required between SKUs

Watch Video

First of its Kind Cartoner Debuts Unique Track SystemExperience controlled carton placement and achieve dynamic carton pitch with the JLS TRAK This robotic system features a high-speed track that delivers cartons unlike any other system

Watch Video

Video Preferred Food-Safe Choice for Thermoformer LoadingLoad raw steaks and other meats with speed and accuracy with sanitary end-of-arm tooling and open frame construction See the hygienic Talonreg thermoformer loader at work

Watch Video

Case Study Robotic Lines Clear Peeps Automation HurdlesProduced in the billions PEEPSreg are so fragile and their packaging formats so varied that they resisted automation until a gentle but fast robotic pick and place primary packaging system solved a host of problems at once

Watch Video

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 26: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

26 Collaborative Capabilities

cobot applications Advances in force-sensitivity safety sensors in particular are improving abilities to work safely with humans and aiding diversity of applications

At the same time some packagers are also looking at ways to be more strategic in use keeping in mind some of the existing limitations of safe operation For example traditionally cobots have been marketed as a separate category of robots that are smaller and slower with sensors to interact safely with humans

Another way to approach cobots is as a mode using safe robotics when humans are present to operate in safe speed force direction and envelope When humans are not detected in the workcell the cobot operates in a full-performance uncompromising mode

This newer definition of cobot functionality overcomes the traditional objections and is ideally suited to a wider range of applications that may require periodic human intervention but also benefit from conventional robotic throughput rates

What Packagers Should WatchAs noted cobots typically are ideal for slower applications with a lighter payload mostly for assembly and packing Going forward cobots with improved sensory functions for autonomous motion will become more widely adopted with greater ability to serve more diverse applications and controls will be unified for simpler operation

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 27: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

27 Collaborative Capabilities

Sensor advancements Cobots continue to make use of increasingly robust vision technology Cobot capabilities to process multiple images improves product inspection enables dynamic picking and increases spatial awareness and safety Integrated thermal imaging offers promise to supplement these advanced vision sensor capabilities And tactile sensors such as capacitive skins that react to contact offer a means to improve perception All of these technologies set the stage for safer collaborative interactions

Integrated unified controls Ongoing programming advancements offer much promise as well Developments are being made in comprehensive programming capabilities that utilize a universal language in a simple visual PLC interface Robot safety

is increasingly integrating with the entire machine safety together Also focus is on controlling multiple cobots using a single PLC including sequence programming

Flexible learning Cobots of the future will utilize AI and virtual modeling to learn optimal process and movement parameters Some researchers are exploring one-shot learning which is where a cobot can recognize an object itrsquos never seen before without a huge repository of training imagery simply by watching a human or using virtual reality gesture control This type of machine learning ability will drastically improve the flexibility of cobots improving ability and speed in switching between tasks (Source ldquoThe Future of Collaborative Robotsrdquo Robotic Industries Association 2019)

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 28: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

28 Collaborative Capabilities

Case Study CobotsOEM Uses Cobots Safely with Its Workers and Improves Efficiency by 30

The project A company that makes tooling (sharpeners

for knives drills etc) used cobots for repetitive and

ergonomically unfriendly tasks in its lines

The process After successfully using cobots

upstream in its manufacturing process the company

brought in cobots for case-erecting and case-packing

functions as these fast-paced tasks were too

physically demanding to do manually over extended

periods of time With the packing system the cobot

removes a die-cut corrugated shipper and folds it

into shape It then places the folded box on a staging

platform pushes it into a squeeze chute that holds

the shape of the box without the need for tape grabs

four individual cartons as they arrive on the conveyor

and loads them into the case Once the case is full

the cobot closes the lid and pushes the case through

a taping station for both bottom and top taping The

cobot is flexible enough to be able to take on multiple

packing configurations

Key to productivity is the systemrsquos interventional

capabilities As cases arrive into the case-

packing station they are taken via a conveyor to a

checkweigher where they are weighed to ensure

there are no missing or extraneous items within

the carton If under- or over-weights occur a signal

from the check station is sent to the cobot to set

the carton aside Instead of just alarming out and

stopping the entire line the system is able to remove

the case and go right back to production

continued on next page

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 29: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

29 Collaborative Capabilities

Also safety features are built into operations

When an operator enters the case-packing area a

sensor slows the robot and the system becomes more

sensitive to external inputs When operators donrsquot need

to be in the case-packing area then the manufacturer

can have the cobot running at full speed

The result The company has seen a 30 increase

in productivity on its line using the cobots Instead

of building product on the lines twice a week the

manufacturer can now build it four times per week

And the company has also benefited in labor use

With fewer staff needed to run the line it can refocus

employees on more complex product areas or

packaging tasks better-suited to human intervention

All told it took less than a year for the cobots to pay

for themselves

Case Study Cobots Continued

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 30: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Universal RobotsAnn Arbor MI

With over 44000 units installed around the world Universal Robots is the market leader in collaborative robots Since introducing the worldrsquos first commercially viable cobot in 2008 UR has developed a product portfolio including the UR3 UR5 UR10 and UR16e

Universal Robots is automating every manufacturing industry thanks to its quick setup and intuitive programming

Headquartered in Odense Denmark UR operates out of US offices in Ann Arbor MI Long Island NY Dallas TX and Irvine CA

Learn more at wwwuniversal-robotscom

White Paper Cobots amp Lean Integrators This paper discusses how developments in robot technology have led to lean integrators whose unique structures and focused expertise are delivering automation to small amp medium enterprise

Read How

Case Study Coty Cosmetics Saves over $500K with Mobile Cobot SystemAt this worldwide cosmetics companyrsquos Maryland factory cobots on mobile carts pick and pack products at the powder presses The mobile solution now delivers $500k in annual savings

Watch How

Palletizing Deployment Guide This guide takes readers through the analysis of an existing manual palletizing process followed by the design and deployment of a collaborative robot application to automate the task

Learn How

Case Study Darex Finds Success in Cobot Box Erecting Improves Efficiency 30Darex solved their labor challenges in Ashland Oregon by deploying a UR5 cobot in a multi-step box erecting application and screwdriving station resulting in 30 productivity gains

See How

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 31: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robotics Packaging Playbook

31

Mobility

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 32: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

32 Mobility

Mobile robots also known as untethered or wireless robots are designed to move around the

manufacturing floor to complete tasks Most are commonly used for transporting products or materials and are popular in warehousing and logistics applications Mobile robots offer far greater levels of uptime over manual labor and can therefore lead to major productivity and profitability gains in warehouse and distribution settings

Although approaches to mobility vary most mobile robots are able to move safely based on their particular use of sensors and the following capabilities

bull Localization mdash determination of where a mobile robot is located with respect to its environment

bull Odometry mdash use of data from motion sensors for the robot to estimate change in position relative to a starting location over time

bull Mapping mdash a robotrsquos use or ability to construct a floor plan to localize itself and its recharging bases or beacons within the plan

bull Navigation mdash a robotrsquos ability to move toward a goal based on self-localization path planning map building and map interpretation

bull Obstacle detection and avoidance mdash meeting a control objective around recognizing and fulfilling non-intersection or non-collision position constraints

Depending on the sensors and algorithms used a mobile robotrsquos estimation of its location and surroundings may be more or less accurate Also size of the mobile robot often dictated by payload or energy use demands typically affects level of maneuverability

Current LandscapeSeveral trends in mobile robots are important to note

Safer movement In the past few years mobile robots have seen safety improvements with spatial awareness for collision avoidance so operators and robots can collaborate in a safer environment Many mobile robots now have built-in force torque sensors

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 33: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

33 Mobility33

to detect abnormal forces or impacts to stop the robot from encroaching on an object and even take corrective action New tactile sensors also allow robots to detect even minimal contact in the environment

Managing environmental change Potential applications for using mobile robots are also getting broader as movement gets smarter Initially mobile applications were mostly about getting from point A to point B in a structured environment Todayrsquos robots increasingly rely on event and process simulation to be able to manage obstacles lighting variations and changes in the smoothness and uniformity of a surface

What Packagers Should WatchThe technology is coming together for mobile robots to reliably detect their surroundings and more effectively react in real time to take corrective measures These advances combined with continued growth in e-commerce position them for much wider adoption going forward The global autonomous

mobile robots market generated $293 billion in revenue in 2019 which is expected to reach $2206 billion in 2030 (Source ResearchandMarketscom Autonomous Mobile Robots Market Research Report By Offering End User - Global Industry Size Share and Trends Analysis Forecast to 2030 2019)

Improved maneuverability Smaller and faster components mean greater ease of movement And researchers continue to focus on using AI the industrial Internet of Things and cloud capabilities to provide high-level computing power resting within ever smaller solutions

Greater learning capabilities Advances in artificial intelligence and machine learning will lead to improved path planning with remote sensing obstacle avoidance and object recognition Robots of the future will utilize AI and virtual modeling to learn optimal movement parameters Many see a future where mobile robots will routinely be able to operate autonomously without

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 34: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Tip Know That ldquoMobilerdquo Often Means More than Just Getting from One Place to Another

Autonomous mobile robots (AMRs) are known for their unique ability to navigate in an uncontrolled environment with a higher level of understanding via sensors blueprints artificial intelligence 3D or 2D vision and more AMRs are highly innovative compared to a traditional automatic guided vehicle (AGV) which is also mobile but uses wires or magnets to navigate a narrowly defined area

Todayrsquos AMR robots arenrsquot just about transportmdashtheyrsquore recognizing and rerouting when something gets in their way They can often ldquorecognizerdquo and reroute around obstacles even 50 feet away AMRs also have tremendous flexibility as updating path flow often requires little more than quickly changing the programmed ldquomaprdquo the technology is using to navigate

34 Mobility

preprogrammed paths and learn their own routes or change their behavior based on what an obstacle is

Agile mobile robots One of the most exciting advancements with mobile robots is occurring where the technology is being combined with use of robotic arms With an arm mounted on the mobile unitrsquos body these robots can automatically move around the work floor and offer enhanced performance in material handling processes Such picking assistant robots while typically having a low pick rate are well suited to take on overly tedious repetitive tasks in order-fulfillment facilities

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 35: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

35 Mobility

Case Study Mobile RobotsMobile Robots Cut Fork Truck Traffic Improve Safety

The project A company that recycles post-industrial

plastics into reusable pallets and other material-

handling products is using mobile robots to minimize

dependency on temporary workers while improving

worker safety and efficiency mdasheven in an older facility

with uneven floors cracks and bumps

The process The company runs 247 to manufacture

about 5000 palletsday at its 400000-sq-ft facility

It recently automated its line with a six-axis robot

to autonomously unload pallets from an injection

molding machine trim the pallets and stack the

finished products directly onto a collaborative mobile

robot The mobile robot then transports the stack off

the manufacturing floor to a separate staging area

as soon as the job is complete In the staging area

the pallets are checked for quality and wrapped

From that point fork trucks transport the wrapped

pallets to the warehouse and loading docks without

having workers present By using the mobile robot

the company has eliminated fork truck traffic in its

production area creating around-the-clock transport

in a much safer environment

This automated line is intended to be the model

to expand eventually to 11 production lines with a

fleet of mobile robots supporting them on a dynamic

highly efficient manufacturing floor in which each

mobile robot can go where itrsquos needed when itrsquos

needed to keep production flowing

continued on next page

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 36: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

36 Mobility

The result The mobile robot travels about 3 miles

each day supporting one production line easily

managing pallet payload and maintaining stability

even when making turns or hitting uneven surfaces

With 11 lines planned for autonomous material

transport with multiple mobile robots workers and

fork truck drivers will be relieved from many miles of

manual material handling allowing the company to

redeploy those workers to higher value tasks

Case Study Mobile Robots Continued

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 37: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robotics Packaging Playbook

37

Getting Started with Robotics

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 38: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

38 getting Started with Robotics

If your operation is considering implementing robot use you will want to keep a few key areas in mind

bull Needs assessment and selection criteriabull ROI calculationbull Choosing the right robotics partner

Needs Assessment and Selection Criteria The range of applications that can be addressed by robots is expanding beyond more common secondary and tertiary packaging applications to uses within the processing and direct handling of food However there are still limitations to the tasks that can be addressed including when fine and dexterous movements are required or where access to tight spaces is needed In addition robots also (currently) lack the creativity and decision-making ability that human workers can provide

Before any research of robotic solutions yoursquoll want to first ensure that your desired use case is even a good match for automation Conducting

a thorough needs assessment where you review current processes and analyze capabilities gaps is an important first step in any project The more you can clearly define your problem areas the easier it will be to discern best-suited solutions

Also recognize that robot selection varies depending on application For example a SCARA robot may be used for compact pick-and-place movements while Delta robots are often selected in applications that require maneuverability of lightweight objects at high speeds

At a fundamental level parameters you should consider prior to selecting a robot type include

Payload The total capacity of the robot should be greater than the combined weight of payload and end-effector at the end of the robotic arm Although the payload capacity is provided by the manufacturer the additional weight of extra parts that might be attached to the robot arm should also be considered

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 39: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

39 getting Started with Robotics

Working envelope The distance and working space the robot is required to operate within is not only dependent upon distance between the robot and the products being affected but also the number of axis and degrees of freedom the robot must operate in

Footprint Calculate space available on the production line for the integration of a robot This is particularly important when introducing robots on large existing lines

Speed Speed and acceleration rate of robots are critical when considering the desired throughput Overspecification can result in increased costs however manufacturers should consider future-proofing performance in the event that demands on throughput of the line increase

Accuracy and repeatability This is the ability to move to an exact point (sometimes on a micron level) and then the ability to repeatedly actuate to

a programmed point in a work area with accuracy Based on the requirements of an application different robot types may be more suitable

Ability to address environmental conditions Robots vary on ability to work in different workspaces whether itrsquos tackling a rough surface floor with a mobile robot or the need for a gripper that meets hygienic standards Some robots are designed for specific environments

As you begin to talk with suppliers about potential applications with these basics in mind yoursquoll then begin to learn more about differences between types of solutions and more accurately define your project needs and goals

ROI CalculationBuilding a business case for investment requires careful consideration and input from multiple stakeholders Calculating ROI is a mixed bag

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 40: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

40 getting Started with Robotics

when it comes to justifying the cost of robotics but seven areas tend to receive greatest focus

bull Reduced labor costsbull Increased throughputbull Total cost of ownershipbull Improved qualityreduced wastebull Decreased worker injuriesbull Measurable uptimebull Improved precision

Yoursquoll want to establish goals for your project around these factors and ensure that all engineers and executives agree on associated requirements and targets Be mindful not to take on too many areas all at once or too complex of processes Instead focus on aligning your team and gaining buy-in around the most important selected targets with the most simple use cases and only then expand your targets or grow project scope over time It can

be tempting to move full-steam ahead But yoursquoll be far more successful if you walk then run

That said be aspirational and not just practical with plans A key to success for many investing in robotics is to prioritize flexibility With such a significant capital outlay itrsquos important to futureproof what you can As an example many manufacturers will work with their supplier to ensure support for variants beyond initial packaging needs such as working with very small batches or flexing for a different packaging configuration Taking these extra steps can add to initial cost but be a smarter investment if it allows the manufacturer to better increase and diversify its production over time

Also be realistic about costs Although robots can improve the efficiency of production lines they require significant upfront investment The high capital cost is not only from the upfront payment for hardware and software but also includes

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 41: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

41 Trend Mobile Robots

installation integration training and education costs as well as the cost of necessary safety equipment (for example light curtains)

Running costs such as maintenance repair and programming should also be considered which may include the need for additional in-house or third-party expertise Significant advancements have been made by robot vendors in improving the user interface and the ease of programming robots but in many cases a different set of programming skills are necessary This necessitates acquiring new expertise

Integrating robots into a production line can also be a challenge especially on high-speed lines Therefore when considering a robotic solution it is important to calculate the total cost of ownership (Note To get a sense of ROI over time view the Robotics Industries Association ROI calculator at httpswwwroboticsorgrobotics-roi-calculator The tool compares costs of leveraging a robot versus manual labor over the lifetime of a project)

Choosing the Right Robotics PartnerLast but not least yoursquoll want to vet suppliers carefully Some common considerations include

Tip Ask About Purchase Options

As affordability is explored speak with your supplier about purchase options For example growing in popularity the robots-as- a-service (RAAS) model has proven a viable alternative to heavy upfront investment in robotics especially for small and medium operations In these arrangements the user purchases a package of recurring fees that often includes maintenance and cloud data management services and in exchange are provided with robots to supplement their production processes

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 42: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

42 getting Started with Robotics

Markets served and applications addressed How experienced are the suppliersrsquo engineers and technicians in relation to the particular robotic class How innovative does the supplier tend to be in this area How familiar are they working with your particular industry application What advice and options do they have for best future-proofing your particular project

Service Although the reliability of robots has improved substantially over the years all solutions are still susceptible to mechanical problems How will your supplier be able to ensure your line is up and running again What does support in your area look like How difficult will it be to access needed parts What sorts of warranties are available

Training What sorts of training support does the supplier provide Will this training involve working directly with their technicians How can the supplier help ensure your operators feel most comfortable working with the technology on a day-to-day basis What does the roadmap for future training look like

The right supplier partner will want to ensure that yoursquore happy with your solution investment and the relationship not just at the time of purchase but in the years ahead

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 43: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

Robotics PackagingPlaybook

43

Bonus Section

Making Sense of ANSIRIA R1506 and ANSIPMMI B1551 Bruce Main PE CSP

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 44: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

44 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

When getting started with robotics often a question

arises as to which standard(s) apply to a machine Or stated differently ldquoIs this a robotic system that does packaging or a packaging machine that includes a robotrdquo

The answer is important because different standards may have differing requirements Standards that may apply to a robotic packaging machine include

bull ANSIRIA R1506 for robotsbull ANSIPMMI B1551

for packaging and processing machinery

bull ANSI B201 for conveyorsbull ANSI B1119 for safeguarding

Other standards may apply as well Depending on which standard(s) is applied the requirements for machinery safety may differ To recognize the right approach for your organization itrsquos helpful to understand how standards are structured which responsibilities and requirements are associated with the standards and ISO restrictions

Standards structure A hierarchical structure to industry standards tcan assist in addressing the issue of guarding This structure is explained in the Foreword to ANSIPMMI B1551 Safety requirements for packaging and processing machinery (2016)

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 45: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

45 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

This structure is derived from the identical ISO structure (see ANSIPMMI B1551 right)

The robot and conveyor standards are all type C standards ANSIPMMI B1551 is a hybrid type A and type B standard The type C standards would generally take precedence over ANSIPMMI B1551 due to the following common premise

However one of the challenges of type C standards is that they tend to lag behind the state of the art The fields of robotics and automation are dynamic and

When a type-C standard deviates from one or more provisions dealt with by this standard or by a type-B standard the type-C standard requirement generally takes precedence Any deviation in conforming to a requirement of any standard should be carefully evaluated and based on a documented risk assessment

The ANSIPMMI B1551 standard can be associated with the ISO A-B-C levelrdquo structure as described immediately below and as shown in Figure 1 below

Type-A standards (basis standards) give basic concepts principles for design and general aspects that can be applied to machinery

Type-B standards (generic safety standards) deal with one or more safety aspects or one or more types of safeguards that can be use across a wide range of machinery

Type-C standards (machinery safety standards) deal with detailed safety requirements for a particular machine or group of machines

The ANSIPMMI B1551 standard on general safety requirements common to packaging and processing machines is primarily an ldquoA-levelrdquo standard in that it applies to a broad array of packaging and processing machines and contains very general requirements However in many areas it also contains very specific requirements typical of a type-C standard

C

B

AFigure 1 - A B C Organization of Standards

B1119 B11 Technical Reports

General B1551 Requirements

Machine-specific standards

ANSIPMMI B1551

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 46: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

46 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

changes occur rapidly For example mobile robots have been in use for several years but the industry standard for mobile robots R1508 is only being published in mid 2020 If your application does not fit the traditional robot scenario what can you do

Which standards to use ANSIPMMI B1551 can be used for packaging and processing machinery that include robots ANSIPMMI B1551 specifically refers to ANSIRIA R1506 as shown

One of the many benefits of applying ANSIPMMI B1551 as the primary standard and ANSIRIA R1506 as an adjunct standard is the responsibilities and requirements that are specified in the ANSIPMMI B1551 standard

The responsibilities for suppliers and users of packaging and processing machinery are contained in clause 4 of ANSIPMMI B1551

American National Standard ANSIPMMI B1551-2016

719 Industrial Robots

Industrial robots as part of or incorporated into machinery should be constructed in accordance with the requirements of ANSIPMMI B1551 and the applicable requirements of ANSIRIA R1506

4 Responsibilities

41 General 17

42 Collaborative efforts 18

43 Responsibilities of the component supplier machine supplier and the machine user 19

44 Responsibilities of the component user machine supplier 19

45 Qualified persons 20

46 Specifications 20

47 Design construction and information for the operation and maintenance 20

48 Installation commissioning and start-up 20

49 Risk reduction measures 20

410 Operation and maintenance 20

411 Training of user personnel 21

412 Cleaning and sanitation 21

413 Operational working space 21

414 Existing (legacy) equipment 21

415 Modifying or rebuilding machinery 21

416 Suppliers of used machinery 22

417 Decommissioning and life cycle activities 22

418 Personnel responsibility 22

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 47: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

47 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

The requirements of ANSIPMMI B1551 are contained in clause 5 as shown below

The fundamental requirement under ANSIPMMI B1551 is to achieve acceptable risk which is defined in the standard as

5 Requirements for Design Construction Reconstruction Modification Installation Operation and Maintenance of Machinery

51 General

Risks associated with the use operation and maintenance of machinery shall be reduced to an acceptable level

52 Supplier

To meet the requirements of 51 machinery suppliers shall use a risk assessment process such as described in clause 6 in the design construction reconstruction and modificatin of machinery to meet the specific requirements of clause 7

Informative Note a collaborative process between the user and supplier should be employed to determine the hygienic design requirements and should be based on the suppliers risk assessment See Annex A ISO14159 and PMMI B155 TR3

53 User

To meet the requirements of 51 machinery users shall use a risk of assessment process such as described in clause 6 in the operation maintenance and hygienesanitation of machinery to meet the specific requirement of clause 7

54 Installation

To meet the requirements of 51 machinery users and suppliers shall jointly separately or contractually use a risk assessment process such as described in clause 6 in the inallation commissioning and start-up of machinery to meet the specific requirements of clause 7

55 Integratormodifierrebuilder

An integrator modifier or rebuilder of machinery shall meet the requirements of 52 See the definition of supplier in clause 3

31

acceptable risk - risk that is accepted for a given task or hazard For the purpose of this standard the terms acceptable risk and tolerable risk are considered synonymous

Informative Note 1 The decision to accept (tolerate) a risk influenced by many factors including the culture technological and economic feasibility of installing additional risk reduction measurs the degree of protection achieved through the use of additional risk reduction measures and the regulatory requirements or best industry practice The expression

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 48: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

48 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

To meet the requirements of achieving acceptable risk requires looking at the specific applications and the risk assessment for them These requirements although general provide some flexibility in the dynamic landscape of packaging and processing machinery automation

ISO restrictions ANSIRIA R1506 is a US national adoption of the international standard ISO 10218-1 and -2 ISO standards are only allowed to contain requirements for machinery builders not end users The rules of standards development under ISO differ then in ANSI in the US in two key ways

bull Products liability Although international ISO standards are primarily written around the legal

structure of the European Union This means that the language used is not necessarily written with a consideration of how it might be used or misused in the US legal system More information is available at Product Liability Prevention Guide

bull Legacy machinery ANSIRIA R1506 does not include responsibilities or requirements other than for new robotic systems Under the ISO rules the standards are not allowed to apply to legacyexisting machinery As such ANSIRIA R1506 does not contain such requirements There are no such restrictions under the ANSI rules and ANSIPMMI B1551 includes guidance and requirements for both legacy machinery and suppliers component suppliers and end users of packaging and processing machinery

RecommendationPMMI recommends that machinery users apply the ANSIPMMI B1551 standard to the packaging system as a whole and make use of the type C standards

acceptable risk usually but not always refers to the level at which further risk reduction measures or additional expenditure of resources will not result in significant reduction in risk

Informative Note 2 The user and supplier may have different level(s) of acceptable risk

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2

Page 49: packaging robotics playbook€¦ · learning, which is where a cobot can recognize an object it’s never seen before, without a huge repository of training imagery, simply by watching

49 Making Sense of ANSIRIA R1506 and ANSIPMMI B1551

as useful guidance to meet the requirements of ANSIPMMI B1551

There is often an inclination to choose the safest alternative out of an abundance of caution This often occurs with decisions about control system reliability ndash selecting PLd or Categery 3 when a lesser specification may be sufficient There are cost implications to such conservative decisions and not just the initial purchase More complex or higher reliability control systems are usually more difficult to troubleshoot diagnose and maintain The standard(s) used will often determine these kinds of requirements thus the proper application of the standards is important

In closing ANSIPMMI B1551 can be used for packaging and processing machinery that includes robots and robotic systems By applying the ANSIPMMI B1551 as the base standard and drawing on the specific applicable requirements of ANSIRIA R1506 machinery users will be able to obtain the best of both worlds ndash packaging and processing machinery with automation

Knowing how to apply the industry standards can assist in developing productive safe and effective solutions PMMI can assist contact Tom Egan vice president of Industry Services for PMMI the Association for Packaging and Processing Technologies at teganpmmiorg

Other Resources

ANSIRIA R1506 (2012) Safety requirements for industrial robots and robot systems

ANSIPMMI B1551 (2016) Safety requirements for packaging and processing machinery

Packsafe risk assessment software

Product Liability Prevention Guide Part 1 and Part 2