Smart factory automation, vol.1 by Coesia S.p.A.

SMART FACTORY AUTOMATION Volume 1

An eBook by FlexLink

INDEX Introduction ........................................................................................

Cobot - a new way to automate production flows ...........................

How to reduce product damage in production.....................................

CHAPTERS Advantages of industrial automation ...................................................

AUTHORS

Four trends that affect the way we produce our food ........................

Fredrik Boberg ..................................................................................

Sustainable automated production flow solutions .............................

Eléonore Bouyenval ..........................................................................

Industry 4.0 in automated productions flow solutions .......................

Klas Ålander ......................................................................................

How to minimize changover time in production ................................

Birgitta Bergström ............................................................................

Hygenic design - reduces bacteria in the food industry ....................

Göran Abbestam ..............................................................................

Production trends that affect the durability of a product ...................

Ulrich Kreimeyer ..............................................................................

Avoid reinfection by using the right cleaning technique ....................

Philip Mulrane ..................................................................................

Why is it important to monitor performance in production line?...........

34 Contact info ....................................................................................

With this conveyor system we are very well equipped for the future .....................................................................................

New articles every month on our blog

Coesia is a group of innovation-based industrial and packaging solutions companies operating globally, headquartered in Bologna Italy, owned by Isabella SerĂ gnoli. Coesia companies are leaders in advanced automated machinery and packging materials, industrial process solutions and precision gears. Our customers are leading players in aerospace, consumer goods, electronics, healthcare, luxury goods, pharmaceutical, racing & automotive and tobacco. Find out more about Coesia on www.coesia.com

WELCOME! Consumer markets continue to push manufactures and machine producers to adapt to new technologies and processes to achieve the highest levels of efficiency. The Internet of Things drives mass customization and sustainable production, which in turn focuses on the reduction of waste and responsible management of natural resources. FlexLink is a world-class factory automation expert. We work closely together with our customers, providing innovative, automated solutions to produce goods smarter, safer and at lower operating costs. For more than 35 years, our solutions and services have enabled manufacturers, machine providers and system integrators to take control of production efficiency. “Knowledge is nothing if not shared” – with our first book, we take the initiative to share our experience and genuine industry know-how. We hope that it will inspire you and solve your challenges. If you cannot wait until the next volume, you will find new articles in our blog at: blog.flexlink.com. Enjoy the reading!

Mattias Byström CEO, FlexLink

Chapter 1. 5

ADVANTAGES OF INDUSTRIAL AUTOMATION Automation has played a significant role in the manufacturing industry for decades. Ever since the industrial revolution, to be precise! And the role will only expand in the years to come. On the next pages you will find 9 advantages of automated productions flow.

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1. Minimizing non-value adding operations and bottlenecks Automated production flows enhance the efficiency of processes by minimizing non-value adding operations and bottlenecks. All handling and manipulation of products is done on the fly and does not require the additional intervention of operators or other equipment. Investing in automated production equipment creates a valuable resource for large production volumes, and increases the overall productivity. This in turn, reduces costs and increases profitability.

2. Standardization of the production process based on best practice In automated production flows, all products are handled the same way, with a minimum of variance. Line layouts built on standardized functions increase your production efficiency and make sure products follow the process path in a seamless, wasteless way. A predictable material handling process reduces work in progress and enables high throughput, ensuring consistent quality and long-term efficiency.

3. Minimizing throughput time and balancing the production flow Automated production flows minimize the throughout time by reducing waiting time and unnecessary buffering. Sophisticated, automated production flow solutions can balance the flow from A to Z dynamically, increasing the total production line efficiency. Buffers, diverters, mergers and dynamic speed control, let the line breathe and prevent queuing on the line. Through automation, you can easily distribute the flow to ensure that the right amount of products arrives on time at up and downstream machines.

4. Improving quality assurance and maintaining overall quality In automated production flows, the same standards and procedures are applied throughout the process, without variance. Automated equipment and robotics can manufacture and continually repeat consistent final product results. When a machine is programmed to perform a task over and over again, the accuracy and repeatability, compared to manual handling, is far greater. Through automation, the manufacturing processes can be carefully regulated and manipulated in order to maintain overall quality. ÂŠ FlexLink 2016

5. Quality inspection can be made on the fly Automation systems can easily incorporate automatic quality checks and verifications to reduce the number of parts produced out of tolerance. Automation also allows for statistical process controls, ensuring more consistent and uniform products. With integrated inspection devices for quality control, quality checks can be made on the fly, and defective units are automatically detected and rejected by the production line.

6. Improving quality assurance and maintaining overall quality In automated production flows, the same standards and procedures are applied throughout the process, without variance. Automated equipment and robotics can manufacture and continually repeat consistent final product results. When a machine is programmed to perform a task over and over again, the accuracy and repeatability, compared to manual handling, is far greater. Through automation, the manufacturing processes can be carefully regulated and manipulated in order to maintain overall quality.

7. Traceability can be made on the fly Today, the ability to trace a product through its processing procedures and re-trace it back, is a long-term strategy for most manufacturers. With automated production flow solutions, traceability can be made on the fly. Implemented traceability programs give you access to track and trace functionality. You can manage all resources in the assembly process including operators, machines, and parts, as well as all the data required for production and quality assurance.

8. Improving factory working conditions and increasing operator safety Implementing automated production flow solutions is an efficient way of preventing operators from getting injured. Automated machines eliminate manual lifting and repetitive work for operators. Robots are also able to work in extreme environments such as areas of high noise levels, which reduces the risk of operators getting injured. In addition, many automated production devices keep operators at a distance from more hazardous areas of work, contributing to keeping operators safe.

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9. Releasing valuable floor space and accommodating products With compact 3D layouts and elevated production flows, you reclaim valuable floor space. This enables you to add more production capacity or increase accessibility for your operators. Refined design and standardized interfaces to the up- and downstream production equipment make the automation solutions highly efficient.

9. Reducing production stops and waste An incorrectly orientated, or dented product can cause severe stops or jams in the production flow, leading to capacity losses and increased waste. Automated production flows use different techniques such as tilting, pushing and rotating to orient the products carefully. The equipment is capable of both handle high-speed flows and achieve high levels of accuracy. Careful handling of the products at high capacity makes a significant impact to your production efficiency and reduces waste.

KLAS Ă&#x2026;LANDER Communications FlexLink

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Chapter 2. 9

FOUR TRENDS THAT AFFECT THE WAY WE PRODUCE OUR FOOD Adopting a new diet will undoubtedly change the individual, but what about the larger impacts? In this article, I will describe four food trends that not only affect our health, but also the way we produce our food and what it means in terms of food safety.

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We want to minimize our consumption of salt, sugar and fat Today, we want to stay healthy and live longer. We want our food to be as nutritious as possible and contain a minimum of unhealthy ingredients. Consequently, many food producers reduce the amount of salt, sugar and fat in their products. This may be good for our health, but cutting these ingredients in products, also allows microorganisms to grow. Microorganisms need water to grow, and if there is enough salt, sugar or fat in a product, the microorganisms cannot absorb water. As a result, when you cut these ingredients, you get a product that is much more sensitive to bacterial growth.

We want to eat healthy, unprocessed and nutritious raw food There is a strong trend to keep as many minerals, vitamins and antioxidants in our food as possible. We do not want to over process our food and raw food is becoming increasingly popular. Raw food usually means uncooked food, or more specifically, food in its natural state. Technically speaking, it is food that has not been heated above 42 degrees Celsius, or 117 degrees Fahrenheit. But cooking with 10

low heating temperatures also means that the food is not heated enough to kill all microorganisms. This makes raw food very sensitive and prone to bacterial growth.

We have higher demands on clear, clean and understandable food declarations Clean Label is a monumental trend in todayâ&#x20AC;&#x2122;s global food and drink industry. The consumers want simple food labels and natural, additive-free and organic food. Cutting additives can be done without risks, but when it comes to preservatives it is important to be careful, as a reduction of them may increase the growth of microorganisms. Preservatives prolong the shelf life of food by protecting them against deterioration caused by microorganisms. Reducing the preservative in a product simply makes it more sensitive to bacterial growth.

We eat a lot more exotic food due to globalization Globalization is affecting us in many ways, not least when it comes to food and the changing networks of food supply. We import and handle more and more exotic food from other parts of the world. ÂŠ FlexLink 2016

Bringing these new foods into our own country also means bringing new microorganisms. Sanitation practices for food handling are not equivalent throughout the world. Importing these new foods can move diseases from areas where they are indigenous to locations where they are seldom found or do not exist. The products we produce based on the exotic food are therefore much more sensitive to bacterial growth.

Higher demands on hygiene and food safety in the production process Common to these four trends is that they all affect the way we produce our food. They put tougher demands on the production process because the products are much more sensitive to bacterial growth. Moreover, sensitive products put higher demands on hygiene and food safety in the entire production process in order to prevent foodborne illness caused by microorganisms. This includes not only the handling, preparation and storage of the food, but also the handling of production equipment.

BIRGITTA BERGSTRĂ&#x2013;M Senior Project Manager SP Food and Bioscience

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Chapter 3. 12

SUSTAINABLE AUTOMATED PRODUCTION FLOW SOLUTIONSO For most businesses, saving human and environmental resources has always been a high priority. But is it possible, at the same time, to increase productivity, lower your costs and improve the working environment? When it comes to production flow solutions, it is possible.

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A demand-driven production generates less waste It is possible to create automated production flow solutions that are friendly to the environment. By using a demand-driven production with minimal re-setting time, an automated system will generate less waste. Gentle handling and short throughput time lead to less scrap, and energy consumption is lower because of intelligent control and drive technology. A re-design of lines and long service life increase the chance of reusing an automated system. Another way of generating less waste and environmental footprint is to make compact designs which requires less space with lower fixed costs.

Lower noise and improved operator safety for better work environment A well functioning working environment is important and is often high on the agenda. An important aspect when building automated production flow solutions is improved machine access and reduced walking distance for operators, combined with fewer stairs which lead to reduced risk for injuries. FlexLink develops systems with improved operator safety and clean and well-designed equipment with low noise.

Fewer conveyors will lead to reduced energy consumption FlexLink compared two automated production flow systems in the tissue industry. The first system had 177 conveyors of different lengths and was based on conventional conveyor technology and line control. The second system was based on FlexLink technology and had 63 conveyors of different lengths and was based on a dynamic line control. There are factors in the automated production flow that could be improved. Dislocated products, high energy consumption and noise level, product damages and waste, are a few examples. Fewer conveyors will lead to reduced energy consumption. Fewer transition points between the conveyors will reduce the risk of dislocated or damaged products, as well as reduce maintenance and noise level. A shorter overall conveyor distance will reduce the non-value-adding transportation.

Decreased power consumption in numbers By comparing the first and second system it becomes clear how big the difference can be. In the first system, 60 percent of the conveyors need to run for a specific production set up, with each drive ÂŠ FlexLink 2016

unit running constantly. In the second system, 75 percent of the conveyors need to run with a specific production set up, where harmonic drive enable each drive unit to run 60 percent of the time on average. Basic calculations shows, the first system has a power consumption of 191 000 kWh, and the second system has a power consumption of 51 000 kWh.

Summary of advanced solutions for the manufacturing industry The Dynamic Motion Transfer allows for perfectly balanced flows at up to 1000 products/min. There are many ways to build more sustainable automated production flow solutions. FlexLink develops systems by applying a variety of elements, and when combining these elements, it generates environmental friendly results. Using modular equipment design, makes the system re-usable and in that way causes a smaller negative impact on the environment. Below follows a summary of more tools FlexLink use when developing sustainable solutions:

FOR REDUCED ENERGY CONSUMPTION • Compact innovative layouts with small space requirements. • Layouts with few and short conveyors. • High efficiency drive technology and low friction conveyors.

FOR REDUCED WASTE • Dynamic distribution, line-balancing and product manipulation for improved system efficiency and balancing downstream demand. • Gentle and safe product handling. • Short change-over time. • Long equipment service life.

KLAS ÅLANDER Communications FlexLink

Chapter 4. 15

INDUSTRY 4.0 IN AUTOMATED PRODUCTION FLOW SOLUTIONS To be attentive and adaptable to new technology, are a prerequisite when operating in the fast moving business of the production and packaging industry. The industrial revolution 4.0 pitches robotics, networked data collection and analytics as the next wave of efficiency, and is a prime example of a concept to keep track of. In this article, I will dive into the world of the fourth industrial revolution.

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The fourth industrial revolution promotes the computerization of manufacturing The term Industry 4.0, or the fourth industrial revolution, was first used in 2011 in Germany, and is today a topic that is high on the factory automation industry’s agenda in most industrialized countries. Industry 4.0 facilitates the “smart factory” and is a collective term covering future oriented individualized automation, deep learning and smart technologies, new services and people development concepts. The first industrial revolution mobilized the mechanization of production by using water and steam power. The second one introduced mass production with the help of electric power, followed by the third digital revolution and the use of electronics and IT to further automate production. With the fourth revolution, intelligent networks along the entire production chain can control each other autonomously by connecting different machines, workpieces and systems and be their “digital twin”. Industry 4.0 represents a paradigm shift from centralized to decentralized smart manufacturing and production. It is enabled by intelligent ICT-based machines (Information and Communications Technology), systems and networks, which are capable of independently exchanging and responding 16

to information to manage industrial production processes. This entails new models for businesses and cooperations between companies and institutions.

Total integration between workshop floor, supply chain and business systems Flexible machinery for instant change of product, format and throughput, as well as a seamless interaction of operators, robotics and machinery. By following the concept of Industry 4.0, manufacturing systems will move toward total integration between the workshop floor, the supply chain and different business systems. It will create flexible machinery for instant change of product, format and throughput, as well as a seamless interaction of operators, robotics and machinery. Industry 4.0 will also contribute to the development of smart manufacturing plants and new technologies in open platforms, which is where many companies base their new productions. The industrial revolution 4.0 enables layouts with smart conveying. FlexLink sees good prospects with involving Industry 4.0 in their automated production flow solutions. The concept enables dynamic production capacities and © FlexLink 2016

layouts with smart conveying. The connection of data and flow will be more intelligent when it comes to both the manufacturing process and the end product. It will also open up for new materials and packaging with a more frequent interaction between processes and products throughout the production chain.

FlexLink has a high level of readiness when it comes to Industry 4.0 For FlexLink, Industry 4.0 impacts the business, as well as the organizational and technological development. FlexLink has a high level of readiness and we are constantly adding elements of Industry 4.0 in our solutions. We can also refer to a history of products and solutions that are supporting the elements of Industry 4.0. It includes line monitoring, equipment monitoring, intelligent components with integrated controls, mixed manual and automated production, modular production line elements and engineering tools connecting physical and virtual reality. We have primarily delivered these solutions to the electronics, automotive, optical and medical device industries.

ULRICH KREIMEYER General Manager FlexLink Systems GmbH

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Chapter 5. 18

HOW TO MINIMIZE CHANGEOVER TIME IN PRODUCTION As the market changes, so does the product demand, which in turn affects your production lines. When introducing a new product, extending a production line or increasing a production mix, changeovers need to be fast and efficient. The more you can reuse your original production line investment, the better. In this article, I will describe how you can minimize changeover time and at the same time get a long-term yield on your investment.

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Changeover in the fast moving consumer goods industry In the fast moving consumer goods industry (FMCG), changeovers are becoming more common as product ranges are increasing due to more customizing and the increase of private branding. More retailers want to offer a variety of products, but in smaller batches. However, producing a variety of products also means producing a variety of packaging and labels. Consequently, changeovers have to be carried out every day, or even more often â&#x20AC;&#x201C; and they must not be time-consuming.

In production, every lost minute is a loss of income Investing in new production lines to be able to produce more is a cost. Instead, if you could keep the number of production lines down, and improve the production efficiency, it would give you a great economic advantage. With fast and efficient changeovers, you maintain a flexible production, meaning producing smaller production batches and without having to build finished goods warehouses. You can offer customers more flexible solutions and faster deliveries, while at the same time keeping inventory costs down.

Converting a production line in as little time as possible Changeover time may vary depending on what requirements the customer has on the product. Often you need to remove products and materials and clean the line components to be able to adjust the equipment. The changeover may include everything from changing only the label of a package, to adjusting all components of a production line requiring a complete disassembly of the equipment. Sometimes it is necessary to change from one machine to another to accommodate the product. This might be the case for secondary packaging, where some customers want their products delivered in cartons, and others in plastic crates in different sizes.

How to minimize changeover time in production Minimizing changeover time can be done in different ways. When it comes to the actual transport system, a certain range of products can be run with the same setup. But when the size or shape of the product begins to vary too much, adjustments are required

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Using a puck or a pallet conveyor to avoid making adjustments to the transport system Conveyor functions for puck handling are well suited for handling small, fragile products. A pallet conveyor can handle a variety of products, from hard disk drives to railway engine bearing units. One common solution is to use a puck. A puck is a carrier that stabilizes products on the conveyor line. The individual product is placed in the standard puck enabling you to switch products without having to make any adjustments to the transport system. The downside, however, is that you will end up having lots of pucks to take care of once the products are picked up, and return back to the start of the line. You may also need pucks for different products.

Conveyor functions for puck handling are well suited for handling small, fragile products.

In the industrial manufacturing industry, where heavier products often are handled, it is not unusual to use a pallet conveyor to minimize changeover time.The pallet has the same function as a puck. Pallet conveyors can handle products in different sizes and weights.

A pallet conveyor can handle a variety of products, from hard disk drives to railway engine bearing units.

Using guide rail components to accommodate many different product sizes and shapes Another way to minimize changeover time is to use adjustable guide rail components. Guide rails and guide rail brackets guide the products and make it possible to accommodate many different product sizes and shapes. The width of the guide rail brackets can then be adjusted manually (by adjusting each bracket), mechanically or electrically (through

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centralized changeover) or automatically (by using an electronic engine control decentralized on every guide rail bracket).

Advantages of automated solutions and automated production flows Using pucks, pallets and guide rail components are all valid tools to help minimize changeover time. The more you automate your production flows, the less time you need to spend on changeovers â&#x20AC;&#x201C; before (preparation), during (conducting) and after (follow-up). There are a number of automated solutions that can be integrated to a production line to minimize changeover time. One example is using a robot for end-of-line palletizing, another is using pick-and-place robots. As robots, in general, are flexible and have the ability to reprogram for product changes, or re-install in other applications within a factory, they most certainly ensure a long-term yield on your original investment.

GĂ&#x2013;RAN ABBESTAM Product Quality & Maintenance Manager FlexLink Product and Supply Division

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Chapter 6. Chapter 4. 22

HYGIENIC DESIGN – REDUCES BACTERIA IN THE FOOD INDUSTRY For food production to maintain excellent hygiene, all items in the factory need to be carefully accounted for; everything from the workers’ shoelaces to the lamps in the ceiling. When deciding on which equipment to use, it is crucial to choose production flow solutions that are hygienically designed. A hygienic design not only enables, but simplifies the cleaning process – a procedure that is crucial when producing food.

The right choice of equipment can help reduce contagious microorganisms As a food producer, you are responsible for the quality of your products and that the food handling is managed in a correct and hygienic way. The right choice of production equipment can help you along the way. The aim of using hygienic design is to prevent or minimize the risk of exposing consumers to bacteria, toxin, foreign objects and chemicals such as oils and different types of detergents. When designing hygienic equipment there are a number of things to consider. For example, the surface should have a perfect finish so there is no room for microorganisms to grow. The surface should also prevent the build-up of biofilm, be flat and easy to clean. It is important that the equipment is easy to drain without cavities to ensure that all humidity and water vanish.

aureus causing infections and Bacillus cereus causing food poisoning were common prior to the 1960â&#x20AC;&#x2122;s. In the seventies, there were a lot of viruses that were contagious through air but also became more and more common in food. Campylobacter causing diarrhea and Yersinia causing flu-like symptoms were also common. In the eighties and nineties, there was an increase of Listeria monocytogenes that causes the infection Listeriosis. The bacterium has had a lot of impact on hygienic design the last years because it creates a biofilm on the surface of the equipment that is hard to get rid of. In earlier years, all infections came from animals and animal products. Today, it is common to get infections like Salmonella, Intestinal bacteria, Hepatitis A and diarrhea when eating for example sprouts, leafy vegetables, berries and sometimes even from drinking water.

Microorganisms change as well as sources of infections The microorganisms that give us diseases today are not the same microorganisms as previously, since the number of pathogens has increased over the years. Bacteria such as Salmonella, Staphylococcus 23

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Sustainable food production throughout the years Different efforts have been made to secure a sustainable food production. In the 1980â&#x20AC;&#x2122;s it became important to uphold a good hygiene in food production. In the beginning, the main focus was on the fundamental things like keeping track of temperatures, traceability, personal hygiene, education, routines for cleaning and disinfectants. A few years later, the focus changed from controlling the end product to finding the weakest link in the production chain. When entering the twentieth century, it became more and more important to work with the whole food chain. Extensive microbiological risk analyses were conducted all the way from product to consume.

Harmless organisms with negative effect vs harmful organisms that go unnoticed When it comes to food sustainability there are many different quality characteristics to consider; decomposition where food starts to rot, product safety where, for example, minced meat is extra sensitive as well as colour and taste. A certain amount of microorganisms are always present in the food, but the number of organisms can grow. There can be a growing number of lactic bacteria that 24

are harmless but affect the food in a negative way, for example induce a bad smell. Or there can be a growth of pathogenic microorganisms that you are unaware of. The paradox is that the harmless bacteria are often the ones that you can see, or smell, but the harmful bacteria can go unnoticed!

Several factors affect the hygiene result If you conduct a hygiene sample during production, there will be a clear difference in results from the samples you take in the morning compared to later the same day, since the amount of microorganisms increases gradually over time. A successful design of the equipment can prevent leftovers from sticking, but there are a lot of other factors that also affect the hygiene. What type of food you produce and which requirements the food has on air and temperature, as well as where you are in the production process are examples of factors that affect the hygiene result.

Prevent bacterial growth with hygienically designed equipment The equipment manufacturer has a responsibility ÂŠ FlexLink 2016

to deliver products that are easy to clean, while the food producer has a responsibility to actually clean the equipment continuously. Since infections from food get more and more common, it is crucial to keep track of your facilities and cleaning routines. Maintaining an excellent hygiene in the food industry is key, both for your business and your customers’ health and safety.

BIRGITTA BERGSTRÖM Senior Project Manager SP Food and Bioscience

Chapter 7. 26

PRODUCTION TRENDS THAT AFFECT THE DURABILITY OF A PRODUCT Our food habits change as globalization is increasing, the geographical distance is getting smaller, and a lot of people are getting a more active and time-consuming lifestyle. In this article, I will discuss the importance of hygiene in the production process, how the production process has changed, and which production trends that can affect the durability of food.

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Today we produce food in a different way, compared to a few generations ago The food materials, which are the basis of our food, have basically stayed the same for thousands of years. However, how we handle the food materials have changed significantly. Today, we produce very complex food. We mix many different raw materials and turn them into one product. We produce a lot of processed and packaged ready-to-eat food that is easily portable and has a long shelf life. In general, we produce more and more food, and the demands on speed and efficiency in the food production are extremely high.

High demands on hygiene and food safety in the production process Bacillus cereus is a Gram-positive, rod-shaped, aerobic, motile, beta hemolytic bacterium commonly found in soil and food. More people are becoming sensitive to microorganisms. Living microorganisms such as bacteria, fungi and virus are found everywhere, including in food. Microorganisms are too small to be seen with the naked eye, but they are visible under a microscope. Some of them are harmless, but 27

some are harmful and can cause diseases. A person can get sick by being exposed to only a few microorganisms, and this puts extremely high demands on hygiene and food safety in production. It is crucial to keep the equipment and environment in the factories clean in order to eliminate harmful microorganisms and to avoid bacterial growth, as well as to minimize the risk of infection.

Production trends that require high quality and hygiene on the products As our relationship to food changes, the quality and hygiene of the food need to adapt accordingly. There are a number of production trends that affect the way we work with quality and hygiene in food production. RTE-products (Ready-To-Eat) are getting more and more common, where some of the products require long durability. Since the products are prepared, they are often very sensitive and responsive to microorganisms. A goal that many producers have is to be able to store the RTE-products in room temperature. This means tremendous demands on hygiene, since microorganisms thrive in warm temperature, and it only takes a few microorganisms to make a product inedible. Therefore, it is important ÂŠ FlexLink 2016

to have excellent hygiene in the production, to secure a high quality of the products. Centralized production means having one main facility from which the food is transported and distributed. This makes the process of ensuring quality more easy, since there only is one process that needs to be validated, but it also poses a risk since many people could get sick if something went wrong. Long transportations can expose the food to a lot of bacteria. At the end of the transportation line, the products may require some sort of processing, which is a source of variability. Therefore it is required that the products maintain a high quality during the whole transport, until they reach the consumers.

Bacillus cereus is a Gram-positive, rod-shaped, aerobic, motile, beta hemolytic bacterium commonly found in soil and food.

Increasing demands on hygiene due to extra sensitive consumers Another aspect to achieve a good hygienic production process is an increasing amount of population that qualify as extra sensitive. Today, about 20 percent of the population belong to the risk group of being extra sensitive. Those who qualify in that group are elderly people over 65 years old, people that have gone through a transplant, people with a suppressed immune system, pregnant women and infants.

Factors that affect the durability of food during the production process There are many factors to consider when producing and transporting food, that will determine if the food will have a long durability. Already from the beginning, there is a certain amount of microorganisms in the products that will be affected during the production process. It is therefore important to continuously control the products to determine if the food contains a lot of microorganisms and what type it is, as some are harder to eliminate than others. The effectiveness of the production process is important, since it is possible to eliminate some of the microorganisms during production. This happens for instance in the ÂŠ FlexLink 2016

process of pasteurizing milk. Reinfection cause one fourth of all pathogenic outbreaks. Reinfection can be avoided by keeping an excellent hygiene on the surfaces that come in contact with the food during production. That will help to eliminate a proliferation of contagious microorganisms.

A correct production process to avoid bacterial growth during production When studying bacterial growth in a growth curve, there are different elements in the process that will influence how the bacteria develop and how fast it will happen. Time is an important factor for bacterial growth, since the microorganisms grow depending on how much time it gets to thrive. Temperature, water, salt, sugar and fat are also factors that either prevent or enable bacterial growth.

BIRGITTA BERGSTRĂ&#x2013;M Senior Project Manager SP Food and Bioscience

ÂŠ FlexLink 2016

Chapter 8. 30

AVOID REINFECTION BY USING THE RIGHT CLEANING TECHNIQUE It is up to each food producer to ensure the delivery of a safe and sustainable product. To choose hygienically designed equipment is probably one of the most important steps to reach that goal. When choosing a conveyor system to operate in the food industry, there are many aspects to consider. Here are some tips along the way.

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There are different causes why reinfections emerge It is crucial to keep your automated production flow solutions clean when operating in the food industry. The equipment should be cleaned based on four aspects; time, energy, chemicals and temperature. If you clean frequently you don’t need to use as many chemicals and high temperatures as you need if you clean less frequently. One fourth of all pathogenic outbreaks is caused by reinfection. The reasons why reinfections occur depend on a number of things, for example; • Insufficient hygiene when handling the product incorrectly • Cross-contamination • Manufacturing and storing in inappropriate facilities that are not suitable for handling food • Unclean equipment • Infection via personnel

Mould and yeast problems are often caused by reinfections When reinfections arise, yeast and mould are often big parts of the problem. A few examples of reinfection caused by unclean equipment due to a substandard design are; when bread gets an abnormal odour, hot dog buns get mouldy and when yeast starts to grow on sliced bread. If you suffer from reinfection you have a great amount of work ahead of you to sort it out and address the problem. The above scenarios are examples of open equipment and open production. In a closed production with closed equipment, the problem could be ten times worse, with a number of pipes, nooks and crannies to consider.

How to detect a possible reinfection The first step in investigating a possible reinfection is to identify and describe it. Which microorganisms are present and how did they end up in the products? Can they grow in the products? Are they pathogenic? Different microorganisms have different characteristics, origins and dispersal routes, as well as different potentials to survive the manufacturing process and grow in the products. Other questions you need to answer are the frequency and the extent of the © FlexLink 2016

infection. How often does the reinfection occur? Which products are affected? Is the reinfection more common in a specific time of the year, day of the week, or hour of the day? Which level and concentration does the reinfection have? The second step is to seek sources and dispersal routes. This requires extensive sampling where you need to work systematically and produce samples from the surfaces, from the air, from the water and from the products. As you can imagine, getting to the bottom of this takes a lot of time and work.

Reinfections can emerge in different parts of the factory and at different temperatures Reinfections can affect all types of automated production flow solutions; from inaccessible equipment, refrigeration equipment to equipment that needs dismantling. One might think that areas like refrigerators are safe since they are cold and cleaned often, but there is a lot of humidity inside, which bacteria love. Even in fans and dehumidification plants condensation is often a problem. Conveyor systems in the ceilings may also cause problems. If the hygiene isnâ&#x20AC;&#x2122;t impeccable it might accumulate condensation and dirt, which possibly could drip down and create for 32

example fungus. Also, in floor drains and on the floor, there could be a risk of reinfection.

Characteristics that hygienically designed equipment should live up to There are different requirements from different producers and manufacturers. The requirements also vary depending on what products you produce and the stage of the manufacturing process. A few examples of requirements can be; to keep the equipment clean from microorganisms, organic impurity and allergens as well as to measure the hygienic levels with pressure plates, swabs, ATP-swabs, or protein/ allergen swabs. Due to the high proliferation of microorganisms there are certain aspects that the conveyor equipment should live up to. For the equipment to be easy to clean and disinfect, it should have features such as flat surfaces, no protruding joints and be drainable. All production flow solutions should have hygiene standards as well as recommendations and methods for how to keep it clean.

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The right production flow solution can perform miracles on your hygiene results To sum it up, just as important as it is to keep an excellent hygiene when producing food, it is equally difficult and time consuming to sanitize and clean up in case the bacteria emerge. Therefore, it is crucial to choose the correct automated production flow solution and have a great knowledge of how to keep your factory clean. 33

BIRGITTA BERGSTRĂ&#x2013;M Senior Project Manager SP Food and Bioscience

ÂŠ FlexLink 2016

Chapter 9. 34

WHY IS IT IMPORTANT TO MONITOR PERFORMANCE IN PRODUCTION LINES? Produce more products and receive a higher return on investment with less effort – who would say no to that? By monitoring the performance of your production lines, you will be pointed in the right direction to find any weak links in your production. This article will describe the importance of monitoring, and how it can benefit your production result.

It is important to monitor performance in production lines in all types of businesses Why is it important to monitor performance in production lines, you might wonder? The main argument is simple – you can’t improve what you don’t measure. If you don’t have measurements or data telling you how your production is performing, it is hard to make improvements that can make your production equipment more efficient. The monitoring of a production line’s performance is relevant in all types of businesses, but mainly in the businesses where the margins are tight. In, for example, the food packaging business, where the margins are razor thin, a small increase in effectiveness can make a big difference to your bottom line.

Adapt your monitoring method according to your business and needs Depending on factory and business, there are several ways to monitor the performance of a production line. In theory, the simplest way is to use pen and paper and have someone watching the production line, using a stopwatch. In reality, if you have a complex factory with many machines, this solution is not realistic for anything but a short-term test. Instead, 35

a more suitable and also a more common solution, is to use a software-based solution. A software program delivers useful and detailed information on how your production line is doing and where there is room for improvements. The more accurate measuring method, the better your adaptions will be to improve your production line’s performance.

The monitoring of a production line can affect the production result A scenario, for when you need to monitor the performance of your production line, could be when you know that you produce too few products, but you don’t know why. To locate the problem, you might need to measure the performance of individual machines. Let’s say your machine should produce 100 products per hour, and work with 100 percent capacity for eight hours straight. However, after analyzing the monitoring result, you discover that your machine only was active for seven out of the eight hours. The monitoring also revealed that the machine only produced 80 products per hour – and on top of that – 20 percent of the products coming out were scrap! Obviously, the machine’s performance is not what it says on paper. By conducting the © FlexLink 2016

analysis, you identify where the losses are coming from, which will give you an indication of what you will need to do to solve the problem.

Look at the whole picture when analyzing the result When analyzing the result of a performance monitoring, it is crucial to look at the whole picture and view the behaviour of several machines in relation to each other. An analysis of a production line, consisting of five or six machines, could point out one of the machines and state its lackluster performance. That doesn’t necessarily mean that it is that machine’s fault, it could just as well be the machine in front of it that performs poorly. When monitoring the movement of the production line, you might see that the machine spends a lot of time waiting for the machine leading up to it. Thus, the machine spends time in a starved state. Another scenario could be that the machine performing poorly actually works perfectly, but it is the machine after, that is in trouble. The conveyor belt between these two machines might be so full that it can’t fit any more products. It is also important to analyze the result based on time versus frequency. A machine could have a fault occurring a hundred times a day, and each time, the machine would stop 36

for ten seconds. It would be worse though, if the same machine had a fault occurring only three times a day, but the fault would block your machine for two hours each time. In case of a machine break down, your monitoring software should communicate directly with your machines. That enables the machine to show different error codes explaining why it has stopped producing. This method brings you a set of tools that will help rule out different scenarios, and get your production up and running again, decreasing down-time.

MES – prevents mistakes from occurring in your production line The manufacturing execution system, MES, is the Rolls Royce of monitoring. When it comes to a wrapping machine for example, the system can tell you which material are supposed to come in and out of the machine. It clarifies which material that was installed, at what date and time, and even who did it! If a product comes back with poor quality, you can check the material that was used for that production. When installing material in a machine, the MES can scan a barcode on the material to check if it is correct or not. This enables you to prevent mistakes from © FlexLink 2016

occurring. The system can also check a product before entering the next machine on a production line, to see if it is missing any parts or if it has gone through all of the prior machines. This leads to high traceability, which is one of the goals of monitoring.

Produce more products and receive a higher return on investment with less effort A continuous monitoring of your production line will enable you and your factory to produce more products and receive a higher return on investment with less effort. By using the same line and the same machines, you enable a higher production, without investing in new equipment or hiring more people. We, at FlexLink, advise you to monitor your production continuously, to always receive feedback on how your production line is doing. That will enable you to identify the bottlenecks of your factory, decrease downtime and ensure a high overall equipment efficiency. What are your experiences of monitoring your production line’s performance? We are interested in what you have to say – please share your thoughts with us in our social media channels. Visit our website for more information or contact me with any questions.

PHILIP MULRANE Software Product Manager FlexLink

Chapter 10. 38

WITH THIS CONVEYOR SYSTEM WE ARE VERY WELL EQUIPPED FOR THE FUTURE Tasty pancakes or the most worn cap in Sweden? Regardless of what comes to mind when thinking about Lantmännen, their expertise lies in sustainable food production, and taking responsibility from farm to table. FlexLink delivered an automated conveyor system that met Lantmännen’s needs of high flexibility, accessibility and excellent hygiene.

Lantmännen – provides northern Europe with responsibly produced food Lantmännen is an agricultural cooperative, and northern Europe’s leading actor in agriculture, machine, bioenergy and food. The first central compound was founded in 1895, Lantmännen have businesses in about 20 countries’ and they are owned by 29 000 Swedish farmers. Lantmännen focuses on optimizing raw products, ingredients and processes to achieve the best quality of the final product. They do a lot of research on sustainable production, where processes that can create unique products and give an improved quality and durability are requested. With a base in cereals, they refine the farmlands’ resources for a viable agriculture. The company is founded on knowledge and values that have been present in their owners work for generations. By working with research, development and business throughout the whole value chain, Lantmännen takes responsibility from farm to table.

Merged two production units into one without compromising on flexibility and hygiene Lantmännen wanted to merge two production units into one, to gain large synergy effects. Equipment 39

from the old factory needed to be installed together with the existing equipment, without compromising on production flow and flexibility between freezers and packaging lines. The products, which consisted of pancakes and crepes, were unpackaged and therefore fragile and could not be moved from the conveyors after they had begun their journey through the factory. Therefore, hygiene was a top priority for this project. “We needed a supplier with large resources. This project had a very tight time schedule. We had a 10day window for moving the factory and six weeks for the entire installation. Flexibility was very important. The supplier had to be able to design an entire system, including customized solutions. This was essential to us.”, says Tomas Alfh, Teknisk Chef at Lantmännen There was a high flow of pancakes moving around in the factory, so the equipment needed to handle the high flow of products and have high accessibility, to avoid waste. Due to the specific circumstances of merging two production units into one, they needed a supplier that could manufacture customized solutions. Another important factor was that the supplier had to manage the tight time schedule, for both moving the factory and to install the new equipment. © FlexLink 2016

FlexLink customized a conveyor solution based on limited space and a short time frame FlexLink solved the lack of space by using the entire volume in the factory, by installing conveyors from floor to ceiling. Since the pancakes and crepes were unpacked and vulnerable it was of high importance that the handling of the products went smooth and friction-free. To ensure this, we did tests of the transition process from one conveyor to another. We conducted these tests at our own premises, to demonstrate the procedure for Lantmännen before we installed the solution. To meet Lantmännen’s need of excellent hygiene we installed our easy-toclean wide belt conveyors in stainless steel. “It was important that the equipment was designed to enable an easy cleaning process. Maybe it is a bit early to conclude but I can say that so far we have not had to redo any cleaning.”, says Tomas Alfh, Teknisk Chef at Lantmännen. FlexLink had frequent meetings with the customer to fulfill their needs.

Hygienic conveyor design in the food factory When we installed our automated production flow solution, Lantmännen took the opportunity and made some reconstructions in the new factory, and 40

added new machines. That meant there were many suppliers and installations to consider and coordinate the work with. We had frequent meetings with Lantmännen to follow up the work, and on location we had both a project manager and a installation manager, that had a close dialogue with Lantmännen’s project manager. “Our cooperation with FlexLink in this project has been very well structured. There were fixed milestones and clear limits and deadlines. We met every Friday to discuss details already at a very early stage. We defined solutions in order to be well prepared for the installation. A lot of people have contributed greatly. This is clearly about cooperation, both internally and externally.”, says Tomas Alfh, Teknisk Chef at Lantmännen. Fillers and packers were connected due to detailed planning and close communication. One challenge with this project was to make room for all the machines and conveyors in a limited space, and still deliver the required flexibility by connecting the fillers and packers according to Lantmännen’s needs. Another challenge was the short time frame. We had six weeks to finish the whole installation, and the production stood still for ten days. Due to close communication, detailed planning and problem solving, we managed to fulfill Lantmännen’s expectations. © FlexLink 2016

The production doubled their volume through robust and safe transport solutions This investment has led to a factory that today produces double the volume without compromising on capacity, hygiene or flexibility. The factory has a high accessibility through robust and safe transport solutions, and the staff can vary products and packaging types in the same system using minimal conversion. Last, but definitely not least, the cleaning process has become both effective and safe, giving an even and satisfying result. With this investment, the future of LantmĂ¤nnen and their pancakes looks brighter than ever! Watch the system in action by clicking here!

FREDRIK BOBERG General Manager FlexLink AB, Nordic Sales Unit

ÂŠ FlexLink 2016

Chapter 11. 42

COBOT – A NEW WAY TO AUTOMATE PRODUCTION FLOWS How about having a colleague that you know won’t steal your lunch or occupy the restroom? Words associated with robots used to be expensive, complicated and scary, but not anymore. In recent years, a new generation of robots has evolved, called cobots.

Cobot – takes over simple tasks and enables staff development Cobot is another word for collaborative robot. The cobot is a major innovation and has potential of being the manufacturing industry’s’ next big thing. One of its main intentions is not to be a threat to employees by taking their jobs. It is supposed to be a new colleague that assists production staff instead of replacing them. The ambition is that the cobot will take over simple and tedious tasks that are time consuming and backbreaking. In that way it will release human staff so they can evolve and learn other tasks, and continue their development in the production chain. Therefore, the aim is to use the cobot for basic operations, such as pick and place components. Since the cobot is versatile it can also perform more advanced tasks, such as palletizing.

Built-in sensor make the cobot sense a person’s presence and location A cobot often operates at low load and speed without safety guarding, unlike many other robots. It intends to physically interact with people, in a shared workspace, since the cobot is designed to be safe for people around it. It possesses a very 43

sensitive overload stop which immediately stops a motion if it touches an obstacle. This is to avoid a potential danger or injury. The built-in sensor makes the cobot not only sense when there is a person near, but also the person’s location. This allows the cobot to slow down, work around the person or stop if the situation requires it. When the person moves away, it resumes its work again.

The application determines safety requirements – not the cobot itself If the cobot is going to interact with staff without safety guarding, it limits the maximum load and speed that the cobot can handle. A cobot making contact with a human when moving heavy equipment in high speed, may risk to hurt the person. Therefore, it is the application the cobot is working with that determines the safety requirements, not the cobot itself. Even a fairly safe cobot will need caging if it is working with dangerous loads like sharp knives. Even if it needs caging, thanks to modern sensors, the cage can be small. In that way, valuable floor space can be released which allows the employees to work more closely to them.

The cobot is easy to install which generates low costs without compromising on operator safety The cobot is relatively lightweight and can be moved from task to task if necessary. Another advantage is that programming is very simple and do not require any special skills from the programmer. Anyone who can use a smartphone or a tablet can also program a cobot. Another aspect that speaks in the cobot’s favour is that it is relatively cheap compared to other robotic solutions. They are easy to use and operate, which keep the price down, compared to other alternatives. The cobot doesn’t necessarily need safety guards to keep it separated from humans on the production floor, as commonly seen with robots used in automotive production. By avoiding all safety enclosures, it contributes to lower footprint while not compromising on operator safety.

KLAS ÅLANDER Communications FlexLink

Chapter 12. 45

HOW TO REDUCE PRODUCT DAMAGE IN PRODUCTION Every day, manufacturers around the globe lose millions of dollars to product damage. An incredibly large amount of material goes to waste, not only causing large economic losses, but also affecting our environment. So, what is causing product damage? And more importantly, how can it be reduced? Keep reading to find out!

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Common reasons to product damage in production In general, when it comes to the production process; that the larger the operation the higher the risk of product damage. The primary reason to product damage is misaligned machines and incorrectly adjusted machine equipment. When machines and equipment are not properly aligned and adjusted, the quality of the handling of product components such as bottles, caps or cartons, is lowered, putting them at risk of getting damaged as they are transported through the production line.Changeover is a critical step of the production process. One critical step of the production process is changeover. Changeover may include everything from changing only the label of a package to adjusting all components of a production line requiring a complete disassembly of the equipment. Sometimes, it is even necessary to change from one machine to another to accommodate the product. If a production line is not properly converted, the products may not be compliant to the quality requirements, but discarded as scrap.

Quality requirements for products and tolerances for product damage The quality requirements for products vary depending on the industry and manufacturer. In cosmetics, and especially in perfume production where products often have a high value and the package design is important, the tolerances for product damage are often very small. The tolerances are established by the product ownerâ&#x20AC;&#x2122;s quality department and decide whether a product is allowed to be sold or not. Non-compliant products may include damages such as fingerprints and scratches on caps and bottles, bad snapping or crimping of pumps, non-compliant cellophaning of cartons such as scratches on cellophane or bad sealing, non-compliant product tracking such as bad marking of batch number, or bad labeling.

The consequences of product damage hit the manufacturer as well as the end user The consequences of product damage hit the manufacturer as well as the end userTo manufacturers, product damage means financial loss. When a product gets damaged the manufacturer needs to separate parts that can be reused, for example the liquid, ÂŠ FlexLink 2016

from parts that must be discarded, for example the bottle. This is both time-consuming and impacts the production efficiency as well as the profitability for the manufacturer. When the production doesnâ&#x20AC;&#x2122;t reach set targets because of product damage, batches have to be rescheduled. This may involve late deliveries and not being able to meet customer demands. Worst case, it leads to unhappy customers, which in turn lead to brand damage and lost sales. Moreover, discarded scrap has a negative impact on the environment. Consequently, the manufacturer carries a big responsibility for running the production as smoothly as possible.

How to reduce product damage in production Reducing product damage causes a positive domino effect that stretches all the way from the manufacturer and its customers to end users and the environment.

Automated production flow solutions maximize the accuracy of operations Product damage can be reduced in different ways, but automation is key. Automation programming 47

enables you to control repeated movement of machines. It maximizes the accuracy of operations. Sensor cells and vision systems are efficient tools to detect damages and non-compliant products.

Controlling equipment increase efficiency and reduce waste It is essential to check and control every step of the operation to guarantee the quality compliance of products and the efficiency of the production line. The sooner an error is detected, the fewer damaged products. Investments in controlling equipment are essential to maximize the production efficiency. The integration of HMI allows operators to control production lines and detect and correct errors, preventing products from getting damaged. SMED solutions are excellent tools to minimize changeover time and reduce waste in the production processes.

Maintenance of machines and machine equipment is still important Naturally, the more automated processes, the less need for maintenance. However, maintenance is still important. With preventive maintenance, it is ÂŠ FlexLink 2016

Old package labels

possible to identify misalignment in time, before there is a breakdown. If production lines are kept in good working conditions, chances are higher that you will avoid breakdowns and the consequences that follow. In addition, operators should be informed and trained regularly.

ELĂ&#x2030;ONORE BOUYENVAL Marketing & Sales Assistant SACMO

ÂŠ FlexLink 2016

FREDRIK BOBERG

ELÉONORE BOUYENVAL

General Manager FlexLink AB, Nordic Sales Unit

Marketing & Sales Assistant SACMO

My name is Fredrik Boberg and I work as General Manager, FlexLink, Sales Unit Nordic. I have been working at FlexLink in Sweden since 2008, focusing on sales in the Nordic countries. My work involves adding customer value, and delivering the solutions that the customers need. This requires a high level of service. In my job, I also focus on making sure that my coworkers stay motivated to perform their best each day. My personal interests are sailing and renovating old houses.

My name is Eléonore Bouyenval and I work as Marketing & Sales Assistant at SACMO in France. I started working at SACMO in 2014. In my opinion, the relationship with the customers is a key element to create a successful business. I am passionate about discovering the issues our customers meet every day, and discuss solutions with our team. It is very important to listen to our customers’ needs to be able to suggest solutions that live up to their requirements. In my spare time, I enjoy cooking, practicing English and Italian as well as manual activities such as DIY projects.

GUEST WRITER

KLAS ÅLANDER

BIRGITTA BERGSTRÖM

Communications FlexLink

Senior Project Manager SP Food and Bioscience

My name is Klas Ålander, and I have worked at FlexLink since 1996. Located in Sweden, my focus area is Communications where I work on creating high customer value. With my industrial background and long experience of over 35 years in the business, I am passionate about production. For over 20 years I have had the privilege to work for FlexLink, where one of my tasks is to enable the right recognition for the company among our stakeholders. My personal interests are, besides being with family & friends, sailing and playing music.

My name is Birgitta Bergström and I work as Senior Project Manager at SP Food and Bioscience. SP Technical Research Institute of Sweden is a leading international research institute, where I have been an employee for 25 years. My area of expertise lies within food microbiology and hygiene. I often experience new challenges in my job concerning different microbiological issues, that are not just applicable in the food business, but in other businesses too. When I am not working, I spend a lot of time outdoors, as well as enjoy different food and beverages.

GÖRAN ABBESTAM Product Quality & Maintenance Manager FlexLink Product and Supply Division

My name is Göran Abbestam and I started working at FlexLink, Sweden, back in 1981. I work as Product Quality & Maintenance Manager at the Product and Supply Division. My focus area is product quality and total cost of ownership. Due to my long experience, I have been working with product development and product management through FlexLink’s entire expansion. In my spare time, I enjoy outdoor sports like downhill skiing and golf, as well as spending time with my family.

ULRICH KREIMEYER General Manager FlexLink Systems GmbH

My name is Ulrich Kreimeyer, and I started working as General Manager for FlexLink in Germany, in 2015. My focus areas are Innovation, Organisational Development and Industry 4.0. I have been working in the industry since 1993, in various positions. My expertise involve packaging, automation, management and Industry 4.0. In my job, I find creative solutions and the development of clear and action-oriented strategies very interesting. I am passionate about growth and success within the industry. In my leisure time, I like to read novels and history books, and I also enjoy dancing.

PHILIP MULRANE Software Product Manager FlexLink

My name is Philip Mulrane and I work as a Software Product Manager at FlexLink in Germany. I have been working at FlexLink since 2010, but my career in automation software started in the 1980â&#x20AC;&#x2122;s. It has been exciting to see how solutions have evolved over the years. When communicating with customers, it is vital to understand their domain, and all of their special needs. Finding out more and more about the diverse industries FlexLink addresses is the most interesting part of my job. When I am not working, I like to travel and spend time with my family.

ÂŠ FlexLink 2016