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The factory of the future: A blend of automation, robotics and IIoT
Author : Martin Walder, VP of Industrial Automation at Schneider Electric
08 July 2020
In many ways, the UK food and beverage industry has been built on automation. Automated picking and packing machines have been widespread for years, permeating and underpinning the industry as a whole.
However, these production processes typically feature machines and people working in collaboration. As we move into the next era of factories, the acceleration of automation and digitisation of packaging halls will need to reach new heights for manufacturers to survive.
Fundamentally, automation and digitisation enable manufactures to instantly adapt to changing clients demands, responding with new products, pack sizes, shapes and materials. They also optimise operational activity by reducing the number of manual interactions to improve speed, run time and dependability, while reducing maintenance costs.
When it comes to maximising efficiency and resilience in the new era of smart factories, business most look to create the perfect blend of automation, robotics and IIoT. Only then can they meet the demands of a fluctuating market.
Robotics and the end of PLCs
When it comes to picking and packaging, the traditional Programmable Logic Controller (PLC), with the odd robot or two, has dominated the global control landscape across food and beverage plants for the last twenty years. However, in recent years, as the need for multi-robot picking lines has ballooned, traditional PLC-based control architectures are increasingly being replaced by a new generation of ultra-high-performance motion and robotic controllers, that also have PLC sequence capability.
This new and improved system is not only smaller but is also more flexible and easier to integrate with embedded picking and packaging application templates. These controllers offer increased performance and a faster payback over traditional solutions, making its adoption a no brainer. Ultimately, not only do these controllers outstrip the PLC for this control, but they also offer full IIoT connectivity and provide invaluable digital tools for remote tracking, monitoring, optimisation and remote services including the latest augmented reality support tools.
In food and beverage production, the largest proportion of factory labour resides in the packaging areas. This means greater saving, if automation and robotics can take over the repetitive tasks integrated on the factory floor. There is an ever-compelling case for the use of automation and robotics as access to low cost labour becomes more difficult, the minimum wage increases and there is more focus on health and safety at the same time the cost of the technology is reducing. To stay ahead in this competitive food and beverage landscape, businesses need to think of what technology will get them ahead of their competitors, but also which technology will make their lives easier in the factory.
Enhancing line performance with IIoT
However, ultra-high-performance motion and robotic controllers isn’t the only technology that is having a dramatic impact on the factory floor. Over the last couple of years, IIoT is playing an ever-increasing role in improving uptime and productivity of automated lines. Secondary sensing, predictive maintenance, monitoring, analytics and artificial intelligence have all played a key part on the factory floor, but one technology capturing the imagination of all is augmented reality. With maintenance personnel spending up to 50% of their time searching for information, AR ensures that they have the right information when and where they need it, with no complication.
There are countless benefits to adopting AR on your factory floor. It can range from a heads-up display of real-time production data and KPIs, maintenance data and, in case of a problem, visual guidance on where the fault is and how to rectify it. Operators will be able to improve operational efficiency through augmented reality, enabling operators to superimpose the current data and virtual objects onto a cabinet, machine, or even an entire plant.
Adopting AR ultimately leads to reduced downtime and improved overall equipment effectiveness (OEE) for the machine and the same technology can guide operators through set-up and safety checks. Undoubtedly, AR will revolutionise manufacturing in years to come and businesses must give it serious consideration to reap the full benefits.
The future of the factory floor
As technology develops, the factory floor evolves, becoming smarter, more connected and more efficient. For UK industry to thrive, we must embrace new, ultra-high-performance motion and robotic controllers and IIoT technologies including AR, as well as the software needed to manage it efficiency. Only then will we be able to realise the long term benefits they can bring to business.
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