OAL News
Robotics & Food Manufacturing 4.0. Are you ready?
Whether robots really belong in a food factory is becoming a no-brainer. In order for the food industry to improve and grow, robotics and automation WILL play a major role in the food manufacturing process. Andrea Paoli reveals how robots have taken root so far in our manufacturing systems and are set to revolutionise the food industry in Food Manufacturing 4.0 and beyond.
The value of robotics
Andrea Paoli presented a number of very enlightening figures when introducing the impact robotics will have in the future. Here are a few to set the scene:
The Bank of England in November 2015 predicted that over the next decade, 15 million jobs will be taken over by robots.
In 2020, the robot market is expected to hit a value over $83 thousand million.
It’s predicted that the global saving for using robotics in terms of labour cost is 16%.
By increasing investment in automation by £1.2 billion, this could raise the overall value added by the manufacturing sector to the UK economy by £60.5 billion. This could safeguard 106,000 jobs.
Since the industrial revolution, robots have gone from mechanical production equipment driven by water and steam all the way to cyber-physical systems which integrate computers, networking and physical processes. The degree of complexity of robotics is forever increasing. As you can see from the videos in Andrea's slides, the capabilities of robotics and automation have increased and improved dramatically. Is there anything they won’t be able to do?
So what does Food Manufacturing 4.0 look like?
Robotics and automation have progressed in such a way that it’s safe for them to work in collaboration with humans (HRC systems - Human/Robot Collaborative systems). They can work to full capacity 24/7 producing the same results they’re programmed to complete. This is impossible for humans to achieve to the same degree of accuracy and consistency.
Therefore, there is a massive opportunity for an increase in productivity for food manufacturers due to the reduced cycle and turnaround times. A robot can work within stabilised conditions without human interface. Not only does this improve the health and safety of the factory, it can also increase the shelf life of products contributing to reducing waste which is a very hot topic at the moment!
Working together with the University of Lincoln, OAL has been championing Food Manufacturing 4.0 and have developed a robotic chef APRIL. APRIL is facing up to the challenges food production is facing to introduce a flexible, automated, continuous, high volume system to food manufacturers. Read more about APRIL and her talents here.
How will a future food factory look?
A factory of the future will run on big data being used intelligently to improve decision making and planning. Cloud computing will allow for anything to be controlled, recorded or reported in real-time. With humans collaboratively working together with robots along with all the big data that will be available, factories will be able to optimise production, reduce wastage and improve product consistency and quality.
Join OAL on this journey by helping us educate the industry to deliver disruptive change in manufacturing securing your factory’s future as well as the future of the food manufacturing industry.
Ann Savage on the future of chilled food manufacturing
What is the right environment for chilled food innovation? Ann Savage, former Group Technical Director at Bakkavor, spoke at the Food Manufacturing 2030 Conference on the future of chilled food over the next ten years. Discussing the rise of new technologies including robotics, Ann highlighted the pressing need for food manufacturing to create the right conditions for successful innovation. After discussing a number of the wide-ranging challenges food manufacturing faces including environmental and significant cost pressures Ann stressed the importance of creating the right conditions for innovation in the UK. Collaboration between research institutions, technology providers and manufacturers will be very important in realising new developments. Likewise, further investment is needed in skills to realise the benefits of new technologies.
Ann has seen the tremendous growth of the chilled food market which has leapt from revenues of from £5 billion in 2000 to £11.4 billion in 2014 and is still growing. Discussing the benefits and rise of automation and robotics, Ann highlighted amongst others the following areas of interest:
Longer shelf life
Robots can work within controlled environment with limited exposure to bacteria and allergens often carried by people. There are significant opportunities for improving the shelf life of products, reducing waste and improving the overall safety and hygiene of the factory in this way.
Improve decision making
Automation within a factory can also reduce human decision-making. The collection and intelligent use of big data will allow problems to be resolved before they occur, as their played out in digital factories. This will allow factories to plan further ahead, reduce stoppages and save time on resources.
Farm to fork
Improved data collection and analysis will enhance food safety from farm to fork. Big data applications will enable full visibility of the supply chain with in-line quality checks enhancing protection against errors.
If you’d like to bring these benefits into your manufacturing facility, our experts can help you take the first step.
McKinsey report: where will automation replace humans in food manufacturing
Food service and manufacturing sit at the top of a recent McKinsey report that analysed work activities rather than occupations as a predictor of automation. By identifying jobs with predictable physical work, data processing or data collecting, they were able to assess the technical feasibility of automation. By breaking down jobs by activities, up to 59% of time spent at work in the US is highly susceptible to automation. Further analysis suggested that food service and manufacturing were more suited to automation than others i.e. many activities within food manufacturing are highly susceptible to automation.
Technical feasibility of automation in food
The McKinsey report highlights food manufacturing and food service as highly susceptible to automation due to the activities involved in the jobs (see figure 1). The main driver for this is the high amount of time people spend on predictable physical work. Often in food factories, people will undertake a high number of predictable activities such as lifting product, moving ingredients etc. (see figure 2).
In our experience, the trend fits for our customers who manufacture a smaller range of SKUs and have already been able to automate a high number of the predictable activities. This is in contrast to chilled food manufacturing, where upwards of 40 SKUs can be produced per day and predictable and unpredictable activities become intertwined.
One major part of the puzzle will be splitting out the predictable from the unpredictable physical work, thus enabling higher levels of adoption of robotics. For instance, lifting ingredients into a saucepan is a predictable task but judging the taste of the food requires the expertise of a chef, hence it isn't so susceptible to automation.
We're working with the University of Lincoln to develop robotic systems that provide manufacturers the flexibility to split out the predictable from the unpredictable thus enabling greater levels of automation. APRIL™ the Robot Chef installed at the National Centre for Food Manufacturing enables this flexibility by breaking down activities in a different way to traditional manufacturing processes.
Mckinsey Technical feasibility
Mckinsey industry Feasbility
Food Manufacturing 2030 Conference - APRIL to cook lunch
Get your lunch cooked by a robot and learn what food manufacturing could look like in 2030. Join us and other food industry leaders to ponder what food processing will look like when we're in driverless cars at the Food Manufacturing 2030 Conference at the National Centre for Food Manufacturing, Holbeach, UK on Thursday 13 October 2016.
See the future
The food industry is ripe for change as it faces a perfect storm driven by the living wage, flat line productivity and food deflation. We believe in order to meet these challenges the industry must transform itself with flexible robotics and automation over the next two decades.
Share in our vision of the future and join us on Thursday 13 October 2016; listen to expert speakers and watch demonstrations as we debate food manufacturing in 2030. Designed for senior food professionals, the event is FREE to attend, and we expect strong discussions as we shape the future of our industry.
APRIL will cook your lunch
Our APRIL robotic food processing platform is pushing barriers and attendees will get a taste of the future as she's cooking lunch. Watch the future of ready meal production as APRIL (Automated Processing Robotic Ingredient Loading) effortlessly twirls a pan around the food processing hall combining ingredients, cooking and cleaning with no human intervention.
Expert speakers
We've brought together thought leaders from across the food industry to provide insights into why and how the food industry will change by 2030. Speakers include:
Simon Lushey, Specialist Technical Manager at Marks & Spencer, will be speaking about why innovation is important to retailing.
Ann Savage, Technical Specialist (Former Group Technical Director at Bakkavor), will be speaking about the future of chilled food manufacturing.
Steve Osborn, Food Technology Scout, will be discussing the consumer trends that will shape food manufacturing moving towards 2030.
Andrea Paoli, Senior Lecturer in industrial automation and robotics at the University of Lincoln, will be speaking about robotic technological developments.
More expert speakers are set to be announced.
Who should attend?
The event is designed for senior food processing and industry professionals looking to learn how robotics and automation will transform their food businesses. Expected delegate job titles include:
Managing Director, Operations Director, Technical Director, Innovation Director, General Manager, Technology/Innovation Manager, NPD Manager, Continuous Improvement Manager
Making big data small in food manufacturing
Confused about the impact of big data on food manufacturing? We believe many food manufacturers already have the data and our focus is better directed to the meaningful presentation of figures to deliver operational improvements.
Originally featured as a guest article on www.bakeryandsnacks.com
There’s a lot of excitement about the internet of things (IoT) and big data but realistically many larger food manufacturers already have access to lots of data. When we speak with our customers, often the idea of more data is seen as a distraction. There are bigger opportunities for operational improvements in presenting data in an informative and actionable way. For big data to be a success, data must be more informative, actionable and timely.
OAL big data bakery SCADA screen
Informative big data
What use is all the data about a process if it’s not easily understood by engineers and operators? One of the big switches we’ve made on our control systems is how we present data. For instance, when you compare our traditional SCADA screens to our newly developed screens they look completely different. Designed with user experience at its core, the new visuals seek to present information that is much more relevant to the end user. For a bakery process, traffic light systems easily indicate if there are any issues relating to humidity, temperature etc. If they’re all green no worries at all. Likewise representing the flow of product as blocks as opposed to how the system operates clearly indicates bottlenecks and breaks in production.
Actionable big data
Data, no matter what its size, is useful to management, engineers and decision makers when it’s actionable. We’ve brought vegetable preparation lines into the 21st century by providing individual operators a screen with real time yield, production feedback and all their Standard Operating Procedures (SOPs). Previously multiple operators would be reliant on a single beacon to track weight. Now actionable data can be presented on an individual basis to improve yield and performance. For both management and operators, it’s clear if an individual is giving away too much product and both parties have the information to hand to take action.
Timely big data
Reviewing yesterday’s production reports looking for insights leaves manufacturers in a reactive state. Manufacturing excellence requires proactive responses to data. Timely delivery of data removes distractions and allows operators and engineers to focus on the job at hand until required. Simple things like changing the colour of a screen from blue, when the downtime is planned, to red, when the downtime runs over are easily understandable.
OAL Factory Performance Changeover