title of the presentation · solutions theater track a ... there are different degrees of...

— FOOD AUTOMATION & MANUFACTURING CONFERENCE AND EXPO | MIAMI, FL | APRIL 14-17, 2019

Automation & adaptive solutions to meet the

demands of the changing consumer Todd Gilliam, US Segment Leader, Food & Beverage - ABB

— Automation & adaptive solutions to meet the demands of the changing consumer

April 24, 2019 Slide 2

Speaker

Todd Gilliam

– US Leader, Food & Beverage Segment

– ABB

– United States

Solutions Theater Track A 10:15 – 10:45am

—

1 2 3

Mission of session


Points of value

Learn about automation

technologies available today

for the food and beverage

industry

Real-life financial and

productivity benefits of

automation including return

on investment

How these new automation

technologies make mass

customization cost effective -

up to and including batch size

one

—


Global F&B – Future factors

Social

Factors

Intensification of law (e.g. Food Safety, Security)

Democratization

Conflict, Terrorism

Globalization

Global economic growth, rise of middle class

Rising economic weight of Asia, MENA

Emerging Service Society, (information,

knowledge)

Rising productivity,

shorter product lifecycles

Global Warming

Resource availability e.g. energy, materials

Energy consumption

Electrification, renewable energies

Autonomous & collaborative systems

Wireless networked systems

Web based technologies

e.g. IoTSP, Cloud

Sustainable materials

SW (AI, VR) replaces HW, Elec. replaces

Mech.

Increase in vision & sensor use

Socio/Cultural Aspects

Health awareness, quality of life

Convenience orientation

Rising demand for safety, security

Ethical awareness

Demographic Aspects

Population growth

Urbanization

Shortage of qualified labour

Migration, people mobility

—

Global trends favor automation

Food & Beverage industry trends


Packaging becomes a key

differentiator

Regulatory requirements,

safety due diligence

More sustainable

manufacturing

Emerging markets, urbanization,

changing demographics

Changing consumer behavior and

purchasing patterns

Changing purchasing patterns of

F&B manufacturers

—

Robot shipments grew by 31% to 381K units while the global economy grew around 3.1%

2017 – the fifth consecutive year of record-breaking growth!


Americas

12% growth, 46K units USA 6% Mexico 7% Canada 72%

Asia Pacific

37% growth, 262K units

Europe

18% growth, 66K units

—

New and traditional trends are both fueling record growth

What is behind this tailwind?


Low volume / high mix the new normal

Agility for shorter product cycles

The importance of engineering efficiency

Critical in capital intensive industries

Reliability important to emerging growth

sectors like food & beverage

Focus on total cost of ownership

Rising labor costs and talent shortages

Quality and consistency

Flexibility The high cost of downtime Cost and productivity

—

What keeps manufacturers up at night?

Accommodating today’s automation trends has consequences


Shop floor disruptions, higher engineering and

commissioning costs.

Higher total lifetime ownership costs from

increased preventive services and planned

downtime.

Lost productivity to maintain safety and less

factory floor layout flexibility.

Shorter product

cycles, more

frequent launches

Increased cost of

downtime and

focus on reliability

Greater need for

human and robot

interaction

Robots play a significant role in helping manufactures meet these challenges.

—

Flexibility to manage the shift from high volume/low mix to low volume/high mix

The challenges & opportunities behind the change . . .


Automation flexibility is needed to efficiently adapt to fast moving market cycles

Economies of scale Mass customization

—

Robots have a critical role in this processing revolution


Efficient at

every level

Reliable and

available

Integrated

ecosystem

The Factory of the Future is characterized by flexibility and enabled by collaboration & digitalization

Flexible

and agile

—

There are different degrees of collaborative operation

Degree of Collaborative Operation

April 24, 2019 Source: Fraunhofer Institute Report Slide 11

All are collaborative operations!

Working on the

same part

Share

workspace

Share

workspace but

not

simultaneously Fenceless

Traditional

cages cell

—

Collaborative Robots are also connected Robots


Safe and flexible collaborative robots are only

the starting point.

The full benefits of the Factory of the Future

will come from Collaboration coupled with

Digitalization - connecting robots to the

broader manufacturing ecosystem

Connected, collaborative robots:

The full potential of the factory of the future is unlocked by collaboration and digitalization

IoT is moving from the consumer

world to industrial automation

—

Collaborative operation with YuMi enables space saving


Panda Confectionary with Trimaster (Multivac)

Finland

Infeed of containers for mixed candy selection

– Collaborative robot enables utilization of confined

space

Reduce labour (4 to 2 people)

Allowed integration in confined space

Eliminated need to alter line layout to incorporate new

product (expensive)

Client

Application

Key drivers &

benefits

Highly compact & flexible and easily transferable to other locations

Achieving Batch Size One

The Adaptive Machine

4th Generation Packaging is Here

Packaging Machinery History

Previous Generations

1st Generation

• Central line shaft with mechanical synchronization

• Changeover were heavily mechanical and time

consuming

2nd Generation

• Servos were added to automate some of the changeover

• More complex machines, but productivity gains were

generally underwhelming.

3rd Generation

• Ground up redesign, leveraging electronic gearing and synchronized motion

• True mechatronic designs with modular mechanical, electrical and software components.

Packaging Machinery History

Today’s Best vs Future’s Potential

3rd Generation

• Modular but dedicated designs

• Changeovers still required

• Mass customization – still elusive

4th Generation

• Mass customization without sacrificing efficiency

• Built for the on-demand market

• Enables digital business models

Why Adaptive Machinery?

A new business model for a new consumer

Today’s consumers have highest ever expectations

The Amazon Effect

• Get exactly what they want

• When they want it

• Delivered where they want

Example: Coca-Cola Freestyle

• Customize soft drink via smart phone

• Innovations in product, delivery system, point of

sale intelligence

A new business model for a new consumer

The Ultimate Goal: Batch Size 1

Already a practical reality in some

industries!

Packing today is closer than ever with

increasingly common requirements:

• Rainbow packing

• Short runs

• Limited time offers

Adapting to the Unknown Reducing time to market for new products and product changes

• Impossible to anticipate disruptive changes over

15-20+ year machine service life

• Switching from glass to plastic or rigid to

flexible today requires completely different

packaging machinery.

Introduction Video

ACOPOStrak Adaptive Machine Technology

Adaptive Machine Design

Strategies & Attributes

Adaptive Machine Key Attributes

Product Transport as a Reusable Asset

• Adaptive machines allow architecture to add track segments and stations to upgrade machine

capacity with reduced investment.

• An attractive alternative to adding machines or replacing outdated equipment.


Redefining Flexibility

Flexibility in Individual Product Control • Variable pitch shuttles

• Elimination of accumulation buffers

• Work on product in transit

Flexibility in Layout & Design • Mount vertically or horizontally

• Circumvent obstructions in plants

• Workspace above, below, inside track


Parallel Processing & Load Balancing

• Traditional fixed-indexing product transport limits line speed to slowest station

• The adaptive machine allows multiple instances of slower stations


Merging Product Flows

• High-speed diverters merge and divide in real time

• Allow for customize assortments


Dividing Product Flows

• High-speed diverters merge and divide in real time

• Allow for rejection or redirection product


Digital Twins & Simulation

• Test multiple variables prior to cutting metal

• Built-in simulation capability

• Customization lies in layout, tooling, fixturing, and optimizing the number, movement and dimensions of

devices, shuttles and workstations

Adaptive Machine Examples

Adaptive Machine Examples

Krones: Bottling on Demand: Capping, Labeling & Packing

Conclusions & Closing Remarks

Final Thoughts

• The 4th generation of packaging machines will bring

collaboration, connectivity and mass customization to the

consumer market through adaptive machine technology.

• These adaptive machines are going to heavily rely on

independently controlled product transport through

multiple processes, including tight synchronization with

other (often robotic) devices.

• New and next-generation linear track systems form the

backbone of the adaptive machine.

—

If you have questions, please contact us further

Q&A and contact information


Todd Gilliam

– ABB

– +1 678-634-6817

– [email protected]

Speaker

Thank You!

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