Smart factory automation, vol.2 by Coesia S.p.A.

SMART FACTORY AUTOMATION Volume 2

An eBook by FlexLink

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

AUTHORS

The MAST Foundation .......................................................................

Patrick Djerf ......................................................................................

Danny Parsons ..................................................................................

Bartosz Kaszyński .............................................................................

Ken Lento .........................................................................................

Jonas Rahm.......................................................................................

Ute Noll ............................................................................................

Anders Ek .........................................................................................

Börje Larsson ....................................................................................

Sven-Erik Eckerström .......................................................................

External contributors ........................................................................

Contact info ......................................................................................

CHAPTERS 6 things to consider when investing in a conveyor system ..................

Friction – positive or negative in automated production flow solutions

Lean improves automated production flow solutions .......................

Top 4 trends in the manufacturing industry in 2017 ..........................

Why traceability is crucial to food manufacturers .............................

“With FlexLink’s elevated conveyor system we can now produce larger volumes” ..........................................................................

Internet of Things in the manufacturing industry...............................

Tray handling technology in the optical industry ...............................

Safety engineering reduces risks and threats in production ...............

How to successdully inplement an automated production flow solution 41 The automotive industry requires stabile production lines ...................

New articles every month on our blog © FlexLink 2017

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

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CREATING THE FUTURE It is by innovation we, Coesia and FlexLink, make a difference. Research and innovation are at the core of our universe and characterize all our decisions, responsibilities and everything we create. It is expressed in the development of new technologies, products, solutions and processes; it affects all our stakeholders. We work closely with customers, universities and communities, to grasp existing and emerging needs, providing essential input to the innovation process. The multi-cultural and multi-disciplinary environment in Coesia is a valuable asset and an important catalyst for our innovation roadmap. Two concrete examples are the Coesia Engineering Graduate Program and the MAST foundation. The Graduate program offers newly-qualified engineering graduates, a highly-technical development path with the purpose of promoting global culture, embracing innovation, growth and sustainability. MAST’s primary mission is to promote and stimulate motivation and interest in innovation, technology and entrepreneurship in younger generations. Read more about MAST in the following article. In our second eBook, we continue to share our experience within smart factory automation and guide the reader through topics such as Lean, friction, Industrial Internet of Things, current trends, and more. We hope that it will inspire and help you with ideas on solving your automation challenges.

Mattias Byström CEO, FlexLink

THE MAST FOUNDATION by Viktor Hermanson

Since the very beginning in 1923 innovation has been a part of Coesia’s DNA. Starting off by streamlining the motorcycle assembly process in the newly founded G.D factory they soon expanded and entered the packaging business. After a short while they launched their very first soap and confectionary wrapping machine – an innovation that brought them global recognition. Today, Coesia is devoted to making new generations interested in creating a forward-looking and innovationdriven future. Believing in the future Coesia - and all of their daughter companies - have since long had a close relationship with their local community and its different charities. Whether it is to raise money to children’s hospitals, support public health initiatives or by integrating refugees with the society via educational programs and mentorships, the Coesia Group is devoted to help bringing the world onward. Owner Isabella Sèragnoli wanted to implement these values more strongly within the company and started planning a project where Coesia could pass on these beliefs and let them flourish. An institution is founded Research and innovation are the core of Coesia’s business universe. It characterizes every business decision they make and every responsibility they take on. The MAST Foundation is a non-profitable and cultural institution for educating, interacting with and creating awareness of the importance of innovation. The goal is to create a prospering society, both environmentally and socially, by encouraging interactions between people and the industry.

By proposing and developing new and advanced projects Coesia hope to trigger and encourage young generations to be a part of the manufacturing industry, wanting to contribute with their own innovations in the future. A center for innovation Since 2003, Coesia had a dream to gather the institution’s activities under one roof by building a hub for it. In 2013 the dream came true – made possible by the architects Claudia Clemente and Francesco Isodori - a state-of-the-art futuristic glass building containing multiple spaces and activities, for both employees and outside visitors, was raised. The MAST Foundation Center near the Coesia headquarters in Bologna stands host to several rooms and halls exclusively dedicated to educating children and students of all ages. An auditorium with seats to hold over 400 people, a company restaurant, a cafeteria, a kindergarten as well a gallery for the public and a wellness center to be used by everyone is also available on the grounds. Planning for the future The MAST Foundations dream and mission; to promote a cultural process that encourages the younger generation’s motivation and interest in mechanics and technology. The synergy between business and community has grown to be more important. To be able to prosper and thrive within the industrial field, as well as in the connected world, new talents are crucial. Coesia lets the MAST Foundation Center be their contribution to the future by implement critical thinking, creativity and entrepreneurship.

Â© FlexLink 2017

Chapter 1. 8

6 THINGS TO CONSIDER WHEN INVESTING IN A CONVEYOR SYSTEM As a production manager, you know downtime is not an option. Most likely, you are constantly looking for ways to optimize your production flows. So when it is time to invest in a new conveyor system, no wonder the task seems overwhelming. It is no secret that there are many things to take into consideration. In this blog post, I will provide you with 6 tips that will hopefully help you make the right decisions.

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1. It all starts with the product and its requirements It all starts with the product and its requirements choosing a conveyor by FlexLinkLet’s just make one thing clear, what conveyor system you should choose naturally depends on the products that need to be handled and its requirements. You need to have a comprehensive understanding of your products, the production process and the production environment as well as system and software. This, along with detailed design criteria, is information that you have to provide to your material handling specialist in order to find out which conveyor system is the most suitable for your production. 2. Don’t judge the book by its cover, look for what is underneath Conveyor systems need to be not only fast and efficient, but also a smart and flexible component of the entire production flow.A few years ago, automated material handling systems were all about conveyance and moving things from one point to another. Today, there is a much larger focus on flow control and keeping the whole facility in balance. Conveyor systems need to be not only fast and efficient, but also a smart and flexible component of the entire production flow. When investing in a conveyor system, look for the right underlying 9

technology that allows intelligent, customised and creative solutions for your production needs. 3. Modularity, scalability and flexibility are important features of conveyor systems The “perfect” conveyor system includes modularity and scalability as well as flexibility. A flexible conveyor system enables adaptation to fluctuations in demand, implementation of continuous improvements and introduction of new products. With standardised modules in a range of sizes and shapes, you are able to retool your production line quickly and easily. When investing in a new conveyor system, look for one that is adaptable to changing product characteristics and volumes, but can also be easily reconfigured if necessary. 4. Easy maintenance with the right technology In a flow-based production facility, any downtime of any step in the process will disrupt the entire fulfilment engine. Consequently, your conveyor system needs to be geared for redundancy and easy maintenance. Technology that provides information about conveyor status and wear indications helps you reduce unplanned downtime. The ability to monitor the overall flow of a facility in real time is a powerful tool for efficiency and uptime. © FlexLink 2017

5. Lower the environmental impact and increase the total efficiency Today the environment is something we all should take into consideration when investing in any product, solution or project. By choosing a conveyor system that allows you to reduce waste and energy consumption of your produced units, you will lower the environmental impact of your entire operations and increase the total efficiency of your production. Optimally, choose a conveyor system that is not only energy efficient and protective of the environment, but also easy to recycle and safe to use.

Still not sure what conveyor system to choose? There is no doubt that choosing the right conveyor system plays a significant role for the efficiency of your production. It is a large investment that should be carefully looked into by a professional material handling specialist. At FlexLink, we help you with the planning and evaluation of your investment as well as the selecting and designing of your conveyor system. Our solutions are geared for low cost of ownership and highly reusable, requiring a minimum of maintenance with low power consumption.

6. Be prepared for the future It might be tempting to choose a solution based on what you are doing today, just to get your line up and running. But try to avoid it. It is always more expensive to make changes later than during the initial project. Try to visualise what your production line will look like in a couple of years â&#x20AC;&#x201C; and invest accordingly. In other words, look for a conveyor system that can accommodate future throughput growth requirements and easily adapt to changes.

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KEN LENTO Senior Business Strategist Food and Optical Segment FlexLink, US

Â© FlexLink 2017

Chapter 2. 12

FRICTION – POSITIVE OR NEGATIVE IN AUTOMATED PRODUCTION FLOW SOLUTIONS? Depending on the situation, friction could be experienced as either positive or negative. When pulling out a kitchen drawer you want as little friction as possible, but when it comes to friction between the tires on your car and the road – friction can save lives. In the manufacturing industry, friction can be both a positive and a negative thing.

Friction â&#x20AC;&#x201C; a combination of inter-surface adhesion, surface roughness, surface deformation and surface contamination between two touching surfaces Friction is what you call the force resisting the relative motion of solid surfaces sliding against each other. Factors that affect friction are force, speed, surface roughness, adhesion, lubrication, contamination and temperature, to name a few. It is not a fundamental force, but a result of the resistance between two touching surfaces. The coefficient of friction is a dimensionless value, which describes the ratio of the force of friction between two bodies and the force pressing them together. The coefficient of friction cannot be calculated, but has to be measured in real tests with combinations of different materials. Some materials generally have a low coefficient of friction against most materials, for example ice, and some have a high, for example rubber.

Dry friction vs lubricated friction in automated production flow solutions High and low friction are equally relevant in a production line. On the sliding surfaces of a conveyor, low friction is required since high friction makes the movement harder, requiring more energy which creates more heat and wear. However, on 13

the transporting surfaces of a conveyor belt, high friction is often preferred to secure the stability of the products being transported. There are two main types of friction considered in the manufacturing industry; dry friction and lubricated friction. Dry friction is the relative motion between two dry surfaces, compared to lubricated friction, which occurs when the sliding surfaces are separated by a lubricant. Thus, the surfaces are only in contact with the lubricant and lose contact with each other, leading to low friction saving energy and wear. However, lubricated friction can cause contamination on the products if they come in contact with the lubricant.

There are just as many friction values as there are material combinations There is no such thing as a specific frictional force for a specific material. Friction is something that occurs between two materials and varies depending on different circumstances, such as material combination. If you drag a piece of plastic against certain fluoropolymers the friction will be minimal, compared to if you drag the same plastic against concrete where the rough surface adds to the friction. ÂŠ FlexLink 2017

Additionally, circumstances like force, speed, surface roughness and temperature will influence the actual friction. Consequently, each material combination must be tested before knowing what type of friction that combination will generate in a given situation. However, by adding additives to materials, the frictional force between two materials can be altered. Oil can be added to achieve a lower friction between two plastic materials, and a rubber substance may in turn increase friction. Often, but not always, high friction equals high wear.

FlexLink adjusts friction to fit specific production lines FlexLink has years of experience in calculating and adapting the right friction to the right production flow solution. Different plastic materials affect the friction in different ways, and we continuously test different material combinations to achieve the exact right combination to fit your productionâ&#x20AC;&#x2122;s specific needs. In our test labs, we conduct numerous tests where we investigate durability, energy consumption, wear and noise level, among other things. FlexLink also work in close collaboration with Swerea, one of the leading science institutes in Sweden, to get cutting edge expertise in how to develop and test 14

different plastic combinations. When deciding on what type of friction that is required, we always take into account external factors affecting the friction, such as humidity, dust and dirt. One might be shocked over the impact friction has on a production process, and how many ways there are to adjust friction. FlexLink customizes automated production flow solutions to fit your specific needs, and the friction coming with the solutions is no exception.

ANDERS EK Research Engineer FlexLink, Sweden

ÂŠ FlexLink 2017

Chapter 3. 15

LEAN IMPROVES AUTOMATED PRODUCTION FLOW SOLUTIONS FlexLinkâ&#x20AC;&#x2122;s main objective is to enable an efficient production flow, using as few components as possible. To achieve that, several methods are being used, where one of them is to apply specific Lean principles in their automated production flow solutions. In this blog article, we will describe a few Lean principles suitable in the production and packaging industry, and what impact the principles could have on the end result.

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Lean â&#x20AC;&#x201C; create more value with fewer resources Lean is a management philosophy in how to handle resources. The purpose of Lean is to identify and eliminate all factors in a production process that donâ&#x20AC;&#x2122;t create value for the end customer. Simply put, it is about creating more value for less work. Lean contributes to customizing and improving operational efficiency in an organization, with the goal to reduce lead-time. The principles of Lean date back to the beginning of the 1900s where they started out as an inspiration to a production system adapted for mass production. Since then, the philosophy has had a rapid development and now covers a holistic approach on how an operation can be optimized from top to bottom.

The goal with standardization is to achieve a foundation where processes are predictable. Unit loads and handling methods that are not properly standardized can lead to malfunctions, which must be avoided. The CONWIP system (Constant Work In Progress) means that the start of each product assembly process is triggered by the completion of another, at the end of production line. In that way, CONWIP concerns the entire system. Since conveyor systems are sensible against overloading, the number of unit loads must be limited. The CONWIP method can be applied to optimise the load on the conveyors between your work stations.

Lean principles suitable for the production and packaging industry Conveyors in automated production flow solutions are not only components, but also proper applications that require appropriate methodology. Lean is very well suited and adaptable to the conveyor industry, where the most relevant Lean principles are: Standardization, which is the practice of defining, communicating, following and improving standards. 16

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One-piece flow is very well suited for a conveyor supported production. The principle means that if an operation of a product is completed, that product moves immediately to the next station, instead of processing an entire batch or lot at each operation before moving it to the next operation. One-piece flow is space efficient, flexible and effective, and the solution decreases both lead-time and waiting time. Poka-Yoke is a device that prevents the occurrence of errors, or at least reduces their probability. The goal with the principle is to eliminate human mistakes, prevent defects, minimize the cost of control processes as well as create an error-free environment. This relates to, for example, unevenly placed unit loads, which may cause mechanical blocking in the system. Visual management is a technique where information is communicated by using visual signals instead of texts or other written instructions. The tools provide information and support the production processes, and thereby improve the operations. This enables an effective design of the working environment.

FlexLink applies Lean principles to increase customer value FlexLink implements Lean principles in their automated production flow solutions with the main object to better understand customer needs and fulfill their requirements. Conveyors are traditionally regarded as inflexible connections. By using new modular solutions, a flexible conveyor system can be easily implemented and adapted to customer demands. One of the cornerstones within Lean management is to have consistency, in every step of the way. Therefore, it is important not only to focus on the results but the whole process. This is something that goes hand in hand with FlexLink’s way of working. Applying Lean principles in the early concept phase, in addition to the traditional technical aspects, will benefit FlexLink’s customers a great deal. By using Lean principles, FlexLink aims to increase efficiency in automated production flows and thereby increase customer value. The goal for FlexLink is to create an efficient production flow using as few components as possible.

Coesia launched in 2014 its own Continuous Improvement Program with the objective is to drive all the organization’s units through a never-ending change and improvement cycle in order to always better meet customer and shareholder needs. Today Coesia runs its own Lean Six Sigma (LSS) Academy, with more than 400 people actively working on LSS projects in all parts of the world. Dedicated people are engaged to develop and execute critical improvement projects by using world-class tools to build sustainable processes, resulting in superior performance to meet current and future customer needs. 18

Bartosz Kaszyński BARTOSZ KASZYŃSKI

Lean Six Sigma Black Belt FlexLink, Poland

Contributors Gábor Bohács and Balázs Sztrapkovics © FlexLink 2017

Chapter 4. 19

TOP 4 TRENDS IN THE MANUFACTURING INDUSTRY IN 2017 Thanks to new and innovative solutions, the manufacturing industry is going through a remarkable development. A large interest in environmental-friendly solutions, as well as a growing need for increased production efficiency, have lead to trends such as individually adjusted production solutions, sustainable and energy efficient productions, digitalization and automation. In this article, I will walk you through the top 4 trends in the manufacturing industry.

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Improve production capacity and simplify production processes Individually adjusted production solutions, sustainable and energy efficient productions, digitalization and automation are top trends within the manufacturing industry in 2017. The trends focus on the environment as well as simplifying and streamlining production processes and improving production capacity.

1. Individually adjusted production solutions to fit your specific needs The increasing need for customized products require both flexible, value adding processes and bespoke production flow solutions to match quality and capacity needs. The trend has been increasing in the manufacturing industry for years but it is not until now it can be done in an efficient way. New digital solutions enable production flow solutions to be adjusted to fit specific industries, processes, products and factory plants. In addition, the digital technology allows both software and IT solutions to be adapted to specific production needs in an easier way than before. Individualized products and traceability are strong triggers of this development.

2. Sustainable and energy efficient production flow solutions A growing trend in the manufacturing industry is to use production flow solutions that are energy efficient and sustainable. Instead of using pneumatics we can see an increasing use of electrical motors, that run for example dividers, stoppers and grippers. When it comes to material, we see more customized material combinations with qualities that fit specific production processes. For example, we mix different materials to find combinations that have low friction and energy use, which are common needs in most industries. To find new material combinations many designers turn to nature for inspiration, where for example water repellant plants inspire the production of new materials with hydrophobic behavior. Plastic based on corn or ricin have increased in popularity when manufacturing products that are bio based.

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3. Digitalization helps to avoid unforeseen costs and production stops The digitalization develops the production flow solutions in many ways. It allows the manufacturing equipment to receive as well as send information to each other in order to adapt the production based on the equipmentâ&#x20AC;&#x2122;s performance. In addition, the machines can inform in advance if they detect something that could cause a production fault in the future. That makes it easier to apply preventive maintenance, which helps to avoid unforeseen costs including production stops. When machines share information, it results in large amounts of data. To be able to define trends based on the data, the data should be stored in the same place. Therefore, the majority saves the information in the cloud. The trend of gathering and analyzing data in the cloud allows you to plan your production in a more efficient way, which often results in savings regarding both costs and time. 4. Automation through robotics improves production efficiency The trend to automate production is clear and the use of robotics is increasing, which enhance the production efficiency to new levels. Collaborative robots are increasing in popularity since they can work alongside

humans and be protected by sensors instead of cages or enclosures. Together, humans and collaborative robots get more done, which increases the productionâ&#x20AC;&#x2122;s competitiveness. Both automation and digitalization are especially evident in the automotive industry, which is going through a digital transformation. The cars are constantly developing, turning into smart machines talking to each other. That leads to new elements in the production chain, such as the installation of batteries and computers in the cars. Thus, the digital development of the products affects how the car factories will work with automation in the future.

Stay updated to keep track of new innovation and trends in the manufacturing industry The background to these trends lies in several new innovations that have matured over a long period of time. The manufacturing of electronics in terms of censors and circuit boards has become more cost effective. Also, the software development has taken big leaps in how to make software more intelligent. FlexLink will focus on these trends in 2017 and find new solutions on how to use effective production techniques, how to collect and save data and innovative ways to use robotics in production. To keep up with new innovation and trends, we cooperate with ÂŠ FlexLink 2017

partners such as research institutes and universities that contribute with new and different perspectives. Individually adjusted production solutions, sustainable and energy efficient productions, digitalization and automation are exciting trends in the manufacturing industry in 2017 and we, at FlexLink, look forward to following and driving these trends forward, for the sake of our customers and the industry.

ANDERS EK Research Engineer FlexLink, Sweden

ÂŠ FlexLink 2017

Chapter 5. 23

WHY TRACEABILITY IS CRUCIAL TO FOOD MANUFACTURERS Today, we produce more food than ever before. Due to globalization, there is also the need to transport the food from one corner of the world to another. International food trade brings many challenges to the table, not least for food manufacturers that constantly face high demands for food safety and traceability. In this blog article, I will talk about traceability and why it is so crucial to food manufacturers.

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Tracing the product back to its original constituent parts First of all, let us sort out what traceability is. Traceability is the ability to mark a product with a unique code that allows the supplier or consumer to trace the product back to its original constituent parts in the event of a manufacturing or contamination issue. In the food industry, it may involve which animals were used in a slaughterhouse for meat production, or which batch of raw material grain was used in bread production.

The importance of traceability in the food and beverage industry The incentives to guarantee product safety, quality and packaging integrity, is crucial in the food and beverage industry. If the right procedures are not followed, it may lead to infections and contamination in the food and, worst case, put the consumersâ&#x20AC;&#x2122; health at risk. The manufacturer runs the risk of damaging the brand and incurring extensive product recall costs including logistics, product disposal, consumer complaints and possible lawsuits. The effects of deficiency in traceability are severe and can be catastrophic for the consumers but 24

also the manufacturer. The ability to trace all input back to a final product and rapidly identify work-in-process inventory and finished or sold goods in the event of a product recall, help to avoid potential damage to the brand or a loss of reputation in the eyes of the consumer. Traceability helps to minimize the impact of such product recalls by ensuring rapid and accurate response to any product issues.

Technology used in traceability solutions for the food industry Typical technologies in food manufacturing are 2D barcodes, vision systems, and image-based IDreaders, which are key components in a database process for traceability. Data matrix and QR codes have been adopted in many applications allowing the storage of much more information than in a 2D barcode, such as manufacturer, product ID, lot number, expiry date and a unique product identifier. Also, Radio-frequency Identification (RFID) is a code-carrying technology that can be used in place of a barcode. The RFID-technology was earlier inhibited by cost limitations, but the usage is now increasing. With technology such as 2D barcodes, it is also ÂŠ FlexLink 2017

much easier for consumers now than previously to trace the origins of their purchased products via websites, or by taking a picture of a 2D barcode using their smartphones to open up a website that verifies the product.

Traceability improves the manufacturing process and cuts costs Many food manufacturers are beginning to realize the importance of building an automated manufacturing IT setup to enable traceability in their manufacturing process. This is not only to meet guidelines laid down in legislation by the European Food Safety Authority (EFSA) and U.S. Food and Drug Administration (FDA) as part of the food safety modernization act, but also to improve their manufacturing process and cut costs. Traceability also engages some anti-counterfeiting measures on products to prove its manufacturing process and make product copies difficult to supply.

FlexLink’s production systems meet the higher standards for food safety FlexLink provides automated production flow solutions 25

that meet the higher standards for food safety, and has the ability to employ the use of traceability. We have vast experience of traceability projects for the food and beverage industry as well as other industries with similar demands on traceability and safety. FlexLink’s approach to food production emphasizes strongly on reducing risks of contamination from the beginning. Our systems are easy to clean and, naturally, follow both EHEDG and 3-A SSI recommendations for design and best practices to keep bacteria, pathogens and other contaminants out, thus lengthening the shelf life of your products.

DANNY PARSONS Product Manager FMGC Segment FlexLink, Sweden

Â© FlexLink 2017

Chapter 6. 27

“WITH FLEXLINK’S ELEVATED CONVEYOR SYSTEM WE CAN NOW PRODUCE LARGER VOLUMES” Gefleorten defends its place in the dairy section through its local presence, to both consumers and farmers. To maintain the gained confidence in Gefleorten as a dairy producer, it is crucial for them to deliver the best products possible. Their investment in a new automated production flow solution has increased their output, and made their production more flexible and cost-effective.

Gefleorten – naturally close since 1933 Gefleorten’s dairy association is owned by a hundred local milk producers, and is one of Sweden’s oldest, and smallest, dairy companies. Gefleorten believes in small-scale production, and being naturally close to their consumers. The business focuses on the manufacturing of fresh dairy products, such as milk, sour milk, yogurt and cream products. Gefleorten’s dairy association is certified according to BRC Global Standards for food safety. That means the quality management system is reviewed once a year by an independent party, to ensure the best quality possible of the products. Gefleorten aims to be the best, and natural choice for their customers.

Gain more floor space and better hygiene conditions with a new conveyor system Gefleorten wanted to renew their old and worn-out conveyor system, and replace it with a system with better hygiene. They also wanted to change the conveyors’ placement, since they were on floor level and took up a lot of space in an already limited area. The expected outcome of the installation was to gain floor space, and to make the whole manufacturing process more flexible. Another 28

important need stated by the customer was to install the conveyor system in a short amount of time. The installation needed to be done over a weekend, since production was running throughout the weekdays.

Clear communication and careful planning were key to meet customer demands To understand the customer’s needs, FlexLink had a clear communication with Gefleorten during the whole process. FlexLink delivered an automated production flow solution where the conveyors were elevated, to meet the need of more floor-space. The system delivered full flexibility between fillers and packers, according to the customer’s requirements. The flexibility meant that they could chose which packer that should be connected to which filler. This was required since the connections often change to meet the market’s needs. Trolleys, crates and cases are just a few examples of different packaging alternatives. To manage the short time plan, FlexLink started assembling the conveyors in the ceiling in advance, to save as much time as possible. When it was time to install the conveyors, everything was already in © FlexLink 2017

place, and the implementation was done according to schedule. A challenge when assembling the conveyors in the ceiling, was the limited space due to ventilation, pipes and pillars. Preparation, planning and communication were crucial for the success of this installation. “We chose FlexLink, and the communication with them throughout the project has been very good. We are very satisfied with selecting them as our supplier”, says Jonas Stiegenberg, Technical Manager at Gefleorten.

Elevating the conveyors resulted in higher flexibility in the dairy factory Due to the elevated conveyors, the dairy factory became more open and accessible. This allowed the producer to fit another filler, which contributed to increasing the factory’s capacity. “The expected outcome of this installation was to gain floor space, and we really did. Elevating the conveyors made a big difference in our narrow premises. The available floor space got much bigger, actually bigger than expected. We have saved a lot of time for the operations since the employees’ can, in an easy way, move around in the factory. We have 29

also been able to put in additional machines”, says Jonas Stiegenberg, Technical Manager at Gefleorten. The effects of their new conveyor system have increased their production, as well as lowered their maintenance costs, since the new system runs smoothly with minimum wear. It has contributed to a higher reliability of supply, and a more effective cleaning process. Although Gefleorten is a small dairy company, these improvements gave the company a better chance to defend its position in the grocery stores’ dairy sections.

PATRICK DJERF Key Account Manager FlexLink, Sweden

Chapter 7. 30

INTERNET OF THINGS IN THE MANUFACTURING INDUSTRY You can, without a doubt, say that the Internet has taken the world by storm. Today, everything from your phone in your pocket to the car you drive has turned into smart, connected products. So, why not implement the same idea in the manufacturing industry? The digitalization of your production processes enables you to easier find bottlenecks and make your production as effective as possible.

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Internet of Things â&#x20AC;&#x201C; the infrastructure of the information society Internet of Things, (IoT) is a network of physical devices, such as machines or vehicles, that are embedded with sensors, software and network connectivity enabling them to collect, store and exchange data. Many devices are online today and the number of connected devices are increasing rapidly. In the coming years, the development is expected to focus on collection and storage, making it safer to keep and handle information online. Internet of Things is one of the cornerstones of the fourth industrial revolution. Industry 4.0 is a term introducing intelligent networks that can control each other autonomously by connecting different machines, workpieces and systems along the entire production chain.

Optimize your production and decrease down-time When referring to Internet of Things in the manufacturing industry, it is often called IIoT, Industrial Internet of Things. Internet of Things can accomplish many positive things in the manufacturing industry. For example, it facilitates storage and logistical challenges, gives a good insight in how products are used which contributes to a more customized product 31

development as well as optimizes your production. Collected data tells you how your machines are performing individually and as a group, how much energy they are consuming and the status of your machines. After collecting the data it is analyzed. This enables you to find bottlenecks in your production and receive an overview of how you can use your resources in order to increase the efficiency. This method helps you save your resources, which is beneficial for both your economy and the environment. Energy is a valuable resource that should not be wasted. By comparing different production lines and factories with each other, you can find out why some machines are performing better than others. Based on collected monitoring data, Internet of Things enables preventive maintenance by anticipating when your equipment needs service. This means increased uptime, giving you complete control of your production.

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Implement IoT in your production by connecting one machine or an entire production line Implement IoT in your production by connecting one machine or an entire production lineTo implement Internet of Things on your production line, the most important thing you need is an Internet connection. The installation process is simple, fast and adaptable to your specific needs, whether you want only one machine connected or an entire production line. You can also choose what data you want to collect and what information you want to store. If a machineâ&#x20AC;&#x2122;s capacity would be exceeded, an IoT-based system can warn you by sending an e-mail or a text message. It is up to you to decide if and when you want your system to warn you. This will help you prevent costly damages on your machines and minimize downtime.

Adjust your machines according to your specific production The method requires limited maintenance and service. It is based on a simple and user-friendly interface, enabling easy use for the operators. However, the ones analyzing the data are required to have a broad knowledge of the production processes to be able to draw the right conclusions. A deep understanding 32

of what the data means enables efficient adjustments on your machines to fit your specific business and production. A challenge with Internet of Things is the safety aspect. When storing information in the cloud, secure connections are really important. However, different security solutions are available on the market, making the storing of data as safe as possible.

FlexLink delivers smart, connected production flow solutions The future looks very bright within this area. Many calculations have been made on the future economic revenue of Internet of Things. According to McKinsey, Internet of Things has a potential of generating up to $11.1 trillion a year in economic value by 2025. We, at FlexLink, focus on delivering smart, connected solutions to our customers. We invest a lot in increasing the competence when it comes to connected solutions and we highly recommend our customers to use Internet of Things in their productions.

ÂŠ FlexLink 2017

JONAS RAHM Head of Innovation Processes and Software Development FlexLink, Sweden

Â© FlexLink 2017

Chapter 8. 34

TRAY HANDLING TECHNOLOGY IN THE OPTICAL INDUSTRY A production process in the optical industry needs to cope with not just a high production volume, but also a traceable process that is adaptable according to the market development. The glue that holds it all together is the tray handling system that enables a flexible and cost effective production process. In this blog post, I will describe the optical industry’s requirements on its equipment, and prove that the industry’s wishes can be granted.

Technological evolution and high production volumes in the optical industry Automation and the way trays are handled within optical laboratories have gradually evolved over the past years. The process has evolved from manually carrying trays to powered roller conveyors or gravity push conveyors, to plastic chain conveyors. Alongside the technological evolution in the optical industry, the market has grown with increased production volumes. Starting a couple of years ago, the market made use of a lot of new opportunities, and growth took place across many areas of the industry. The optical industry is now flourishing with a sustained economic upturn. The optical industry had a need for new equipment within tray handling technology Optical market growthIn connection with the market growth, the optical lab landscape changed with the move to new optical technology and lighter load requirements. The changes resulted in a need for a new technological system that had specific qualities within tray handling technology. The requirements on the new system were to produce higher volumes more efficiently, save space, lower running and investment costs, and that the system should be easy to operate and modify to fit specific needs. 35

The need for a new system was not just for the larger high capacity labs, but also the small regional labs that previously may have struggled with justifying the automation investment. A tray handling technology system specifically designed for the optical industry Vision X™ is the only automated conveyor system designed specifically for the needs of the optical industry. The system is based on standard modules, which are configured to fit all key production machines on the optical market. One of the most important features of Vision X™ is the core of the system, a multi-functional “universal tray turner”, affectionately named the spider because of how many conveyors that can come out of the core of the machine. This allows a distribution of trays of up to eight different exit or entry positions, and also 180-degree rotation, which is sometimes required for routing decisions. In addition, it can be installed with a vertical axis, which doubles the number of possibilities and enables the lab to arrange the conveyors in many different ways – allowing unique and space saving layouts. The tray turner is designed to control all the connected input and output conveyors, and it also contains a safety stop for each conveyor. This solution enables the optical labs to conduct creative © FlexLink 2017

conveyor layouts. “It was like learning a new operating system on your mobile phone. At first you might get a little frustrated and then you have that aha! moment and understand how it all works. It’s exciting when you see the results and then you just want to see how much further you can go”, said Rodney Remsey, Director of Laboratory Operations for Classic Optical Laboratories Inc. Classic Optical Laboratories cooperated with FlexLink and went from a manual laboratory to an automated laboratory, with the Vision X™ solution as a key feature. Low noise, high stability and gentle handling of sensitive products In almost all countries, the use of a frequencyweighting is mandated to be used for the protection of workers against noise-induced hearing loss. Another requirement from the optical labs was to reduce the number of devices using compressed air because they create; noise, complexity, dust and higher maintenance requirements. The Vision X™ system features solenoid stops which are electric, instead of pneumatic. That means the system uses no compressed air and thus extremely quiet. In addition to a low noise level, the system provides advantages such as stability and gentle handling of sensitive 36

products. The system requires all the machines to be placed closely together which in turn saves a lot of space in the optical labs. Combining all these features into one unit enables a high level of standardization with high flexibility in tray handling. The unit can even be used to provide an access gate through the line or simultaneously elevate the conveyors to transfer the products between different levels. The simplicity of the system is its beauty – it is fast to install with minimum disruption to production, and it is easy to reconfigure if your system changes. Thus, it qualifies as a cost effective and reliable tray handling equipment that enables a high production rate – all the qualities that were required from the optical industry. “It took a little work to get everything set up, but once it was installed it created huge savings in our labor cost. There is no way that we could have managed to expand to this volume of manufacturing profitably without installing automated materials handling” said Remsey. FlexLink develops solutions based on needs from specific industries Vision X™ is a tray handling system specifically designed for the needs of the optical industry. During the development phase we have had a thorough © FlexLink 2017

consultation process with the industry, combined with many years of experience in automating optical laboratories.

KEN LENTO Senior Business Strategist, Food and Optical Segments FlexLink, US

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Chapter 9. 38

SAFETY ENGINEERING REDUCES RISKS AND THREATS IN PRODUCTION The margin for production errors is constantly shrinking and manufacturers strive for complete control over their production processes. Safety engineering helps you remove threats and protect production processes. It also helps you increase machine safety and maintain a safe working place for the operators. Safety engineering works as an insurance for your production. In a proactive way, safety engineering enables you to protect your assets.

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Safety engineering â&#x20AC;&#x201C; makes safety an integral part of industrial operations Safety engineering is a technology field dealing with safety when it comes to engineered systems and designs. It is applicable in the manufacturing industry and is highly associated with machine safety, industrial engineering and systems engineering, making safety an integral part of industrial operations. The purpose of safety engineering is to control risks and threats, such as contamination, interference, injury, delays and defects by reducing or completely eliminating them. Safety engineering covers both hardware in form of components building up frameworks, fences and enclosures, as well as consultation regarding machine safety, risk assessment and service. Process safety and operator safety in the manufacturing industry Safety in the manufacturing industry distinguishes between process safety and operator safety. Process safety aims to ensure that the production process proceeds without errors or breakdowns. Operator safety, on the other hand, relates to protecting operators from accidents involving individual processes and machines. Safety engineering should be applied early in the production process, during the design phase of a production system or in the beginning of a product development. Before implementing a production 39

system, safety engineers study the manufacturing process under various conditions. To identify possible risks and hazards, the engineers consider factors such as technical safety, material reliability, legislations and human errors. Safety engineering is done individually, because the requirements of each production process is unique. Save time and resources while increasing uptime and output Both operators and machines as well as production processes benefit from safety engineering. Fences and enclosures protect operators from moving devices and goods, including sound emissions. In turn, the enclosures protect the machines from dust and contamination. Disturbances are eliminated when protecting your production processes, which results in less waste while increasing both uptime and sellable output. FlexLink provides flexible and well-designed frameworks and enclosures A safe production is the basis for a standardized flow and a quality assurance. Our customers aim for turnkey solutions by having one contractor deliver a high value when it comes to price, delivery time, design and safety. FlexLink, as a supplier of ÂŠ FlexLink 2017

conveyor systems and profile systems, lives up to all these demands by supporting customers with a team of experts through all stages of the process. We assist you in making the risk assessment, stating the functional requirements, designing the application and, finally, installation and maintenance. To support our customers, we also provide a sophisticated Engineering Tool with integrated logic to quickly design an enclosure or fence. The tool is easy to use and fully interconnected with all FlexLink Engineering tools for trouble-free order handling and assembly. Our goal is to deliver safe and flexible solutions for future adjustments and adaption to new regulations. We design systems that meet your particular needs, enabling a safe working environment for your operators, machines and your production.

UTE NOLL Sales Manager Profile Systems FlexLink, Germany

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Chapter 10. 41

HOW TO SUCCESSFULLY IMPLEMENT AN AUTOMATED PRODUCTION FLOW SOLUTION Automated production flow solutions can differ tremendously depending on production and needs. They can consist of one conveyor connecting two machines together, or a mix of different lines, machines, elevators and robots. Irrespective of size, the goal of an automated production line creates an excellent workflow. In this article, I will describe some of the most important aspects to consider when implementing it, to make the process as efficient as possible.

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Automated production flow solutions can create an optimal manufacturing flow A fully automated production flow solution can create an excellent flow throughout the whole production. An optimal flow often includes several manufacturing machines that are linked together through a system of conveyors. The conveyors distribute the products evenly on the production line at a pace that is adapted to the production. The implementation process consists of several steps and there are many things to keep in mind to be as efficient and successful as possible. Simplify the implementation by using standard contractual conditions The first step is to design an application. The application is based on the supplier’s suggestions of the most suitable production flow solution for that specific customer’s needs. When the customer approves and places an order, one of the first things to do together with the customer is to establish a contract and contractual conditions. The contractual conditions include the rights and obligations of both the customer and the supplier. The conditions cover for example how the installation process should be handled as well as milestones and economic reference points. It is recommended to use a 42

standard contract to simplify the process as much as possible. Special conditions and exceptions can in worst case delay parts of the implementation, which can affect the whole process in a negative way. A standard contract provides a common basis and understanding that is a great help for both the supplier and the customer throughout the implementation project. Conduct a well thought out time plan early in the process Before implementing an automated production flow solution it is important to have a realistic approach regarding the project’s time plan in order to avoid delays. There are often several different suppliers that deliver equipment to the same production line. Therefore, all suppliers need to be coordinated so the different components are installed in the right order and at the right time. Since the conveyor system is connecting all the machines and components together, one should consider installing the conveyors last. Communication is key during the risk analysis One of the most important things to remember during an implementation of an automated production © FlexLink 2017

flow solution is to have a clear communication with all parties throughout the whole implementation process. An example where communication in an implementation process is key is in connection to the risk analysis, which is performed before installation. The risk analysis involves, for example, technical risks in the working environment such as heavy lifts. It also involves specific rules if the production plant is completely new. If the installation will take place in an already existing factory plant and there will be an ongoing production during the installation, the production staff needs to be aware of this, and that requires a high level of coordination. So, it is crucial that all parties involved in the implementation process are aware of the risks and rules coming from the risk analysis.

After installation, the supplier offers education to the production staff in how the production flow solution works including all the features. The implementation process ends with a site acceptance test (SAT) testing the performance of the automated production flow solution. The test shows that the supplier has completed the delivery, and after the test is conducted and approved, the finalized automated production flow solution is handed over to the customer. For the automated production flow solution to have a long service life it is important that the solution gets proper service and maintenance. This is to avoid potential production stops that can cause financial damage to any manufacturing industry. Service and maintenance are either performed by the customer or it can be provided by FlexLink as a part of a service agreement.

A site acceptance test controls the performance of the production line After designing the automated production flow solution a factory acceptance test (FAT) is performed in the supplierâ&#x20AC;&#x2122;s premises, which the customer is invited to take part in. After the customer has approved the factory test, the equipment is packed and delivered to the customer. Upon arrival, an installation team unpacks and installs the production line for the customer.

Increase profit and product quality with robust production equipment It is highly profitable to invest in an automated production flow solution in a manufacturing industry. The solution contributes to delivery assurance and a robust production flow. It also leads to high product quality since the production is performed in the exact same way regardless of production staff, time of the day or day of the week. Also, it is a flexible system that is easy to re-design and has ÂŠ FlexLink 2017

a long service life. FlexLink’s automated production flow solutions are well proven, cost-effective as well as easy to install and maintain. In addition, they are flexible and can handle products in all sizes, from lipsticks to pallets with cartons. During an implementation, we have a tight dialogue with the customer to secure an automated production flow solution that fits them, their needs as well as their production. There is no manufacturing industry that we can’t design an automated production flow solution for. Put us to the test and we will prove it to you!

BÖRJE LARSSON Senior Project Manager FlexLink, Sweden

Chapter 11. 45

THE AUTOMOTIVE INDUSTRY REQUIRES STABLE PRODUCTION LINES The automotive industry has been a successful industry for many years. It is an industry with high delivery requirements and often tight margins. In order to stay profitable in the automotive industry and meet the customersâ&#x20AC;&#x2122; ever higher demands, effective and well-functioning automated production flow solutions are key. This is the first part of two in my article series about the automotive industry and its use of automated production.

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One of the worldâ&#x20AC;&#x2122;s oldest manufacturing industries The automotive industry arose in the beginning of the 20th century and is one of the oldest manufacturing industries there is. Generally, the industry has been and still is very successful, breaking new records every year in the number of sold cars. The automotive industry is also in the forefront when it comes to new digital solutions. We predict a massive change in the automotive industry in the future, where the transition from combustion engines to electrical engines is becoming more and more evident. Eliminate production stops to meet tight margins and stay profitable A production stop in the automotive industry can lead to devastating consequences. Because the industry earns a quite small amount of money per car, it all comes down to quantity, which means they need to produce many cars in order to be profitable. There are high delivery requirements with tight margins, so for the industry to deliver what they promised they need well-functioning production flow solutions that operate without production stops.

Clean and safe environment with controlled handling of heavy products It is important to maintain a clean and safe environment in the automotive industry. Oil spill on the floors must be eliminated to reduce the risk of staff slipping, and clear colors help determine if a surface is clean or not. Also, the noise level should be reduced to a minimum in order to provide a good working environment. Compared to many other manufacturing industries, the automotive industry deals with heavy products, often up to several hundred kilos. The weight can also differ depending on where the products are in the production line. As the products travel through the production line they become more and more refined, which means the production equipment needs to handle more weight at the end of the line than in the beginning. The use of robust and safe production flow solutions is crucial to handle heavy products in a safe and controlled manner, as well as maintain a clean and safe work environment. The automotive industry moves from a mechanical focus to a mechatronic focus The future for the automotive industry looks very bright. As mentioned earlier, the industry is moving towards a new technology where electrically driven

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cars are becoming more and more common. That means the business for mechanical automotive companies will change dramatically the coming years since they need to switch from a mechanical focus to a mechatronic focus. Many believe that by the year 2020, 50 percent of all newly produced cars will be electrically driven. Smart and energy-efficient automated production flow solutions FlexLink has extensive experience in equipping the automotive industry with automated production flow solutions. To find the most suitable solution for our customers we carefully go through their specifications describing, for example, the products, the weight of the products, cycle times and which fluids are involved in the different operations. We are familiar with the industry and how different processes work as well as what type of machines are used in the production line. A comprehensive understanding of the industry and its needs is important in order to deliver the effective and wellfunctioning solutions the automotive industry requires.

SVEN-ERIK ECKERSTRĂ&#x2013;M Product Manager, Automotive Segement FlexLink, Sweden

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PATRICK DJERF

DANNY PARSONS

Key Account Manager FlexLink, Sweden

Product Manager FMGC Segment FlexLink, Sweden

My name is Patrick Djerf and I work as Project Manager Strategic Projects at FlexLink in Sweden. I started working at FlexLink in 1990, and a few of my focus areas are Hygienic Sales & Application and Pre-studies. I am passionate about understanding our customers true and real needs, and convert them into attractive and relevant solutions. The ability to think outside the box is very important, and the beauty often lies in the simplicity. When I am not working, I enjoy music, particularly singing and playing the trumpet, as well as orienteering.

My name is Danny Parsons. I am the Product Manager for the FMGC segment at FlexLink based in Milton Keynes in the UK. I have been working for FlexLink for more than 18 years, and have over 25 yearsâ&#x20AC;&#x2122; experience in FMCG; from design and product engineering to project management and product management. My interests outside of my family include maintaining a fit and healthy lifestyle with a keen interest in football as a player, coach and fan.

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BARTOSZ KASZYŃSKI

KEN LENTO

Lean Six Sigma Black Belt FlexLink, Poland

Senior Business Strategist, Food and Optical Segments FlexLink, US

My name is Bartosz Kaszyński. I am the Lean Six Sigma Black Belt at FlexLink based in Poznań in Poland. I have been working for FlexLink for more than 12 years, and have over 17 years experience in project management. I am passionate about Lean culture, Business Excellence, and Efficiency. I believe that collaborative team effort is able to improve performance by systematically removing waste. In my private time I’m fishing, cooking and love travel around the world.

My name is Ken Lento and I work as Senior Business Strategist in the Food and Optical Segments. I started working in the field of conveying and automation in 1995, and started at FlexLink in 2001. Currently, I am based at the FlexLink US office in Richardson, Texas. In my job, I am passionate about working with and helping our customers, and together create long-term and solid relationships. My personal interest is, in addition to family activities with my wife and three sons, to engage myself in American football for middle to high school aged players. I am also President of a non-profit organization called the Gifted and Talented students.

JONAS RAHM

UTE NOLL

Head of Innovation Processes and Software Development FlexLink, Sweden

Sales Manager Profile Systems FlexLink, Germany

My name is Jonas Rahm. In 2016, I started working as Head of Innovation Processes and Software Development at FlexLink in Sweden. I have a Master of Science in Engineering and over 20 years of experience from software development and organizational development. I am passionate about automation and finding new innovative solutions to complex problems. I believe that Industrial Internet of Things will bring a transparency which will lead to the development of many new smart solutions, which will be economically beneficial for our customers. My personal interest are running in the forest and spending time with my family.

My name is Ute Noll and I work as Sales Manager at FlexLink in Germany. I started working at FlexLink in 2017 and my focus areas are international market development and safety engineering. With my background in engineering and administration, I support our customers in every way I can. I love to travel and meet people from different countries and cultures, so working at FlexLink suits me really well. My personal interests are to travel, ski and ride my motorbike.

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ANDERS EK

BÖRJE LARSSON

Research Engineer FlexLink, Sweden

Senior Project Manager FlexLink, Sweden

My name is Anders Ek and I work as Research Engineer at FlexLink in Sweden. I started working at FlexLink in 2008 and my focus areas are material research and mechatronics. I try to find techniques within these areas that will be suitable for our business in the future. Prior to FlexLink, I worked as an Engineer in the automotive industry for over 20 years. The one thing that motivates me the most is my curiosity. I have to figure out how things work and I can’t wait for my next “aha-experience”. Especially if it leads to helping our customers. In my spare time, I enjoy traveling and spending time with my family. I am also fond of the outdoor life, preferably in connection to water or snow. 51

My name is Börje Larsson and I work as Senior Project Manager at FlexLink in Sweden. I started working at FlexLink in 2007 and my focus area is Project Management. In my job, I am motivated by successful projects. I am also motivated by the teamwork in my team as well as cooperating and keeping a close dialogue with the customer’s team. When I am not working, I spend a lot of time sailing as well as working with my house and garden.

SVEN-ERIK ECKERSTRÖM

EXTERNAL CONTRIBUTORS

Product Manager, Automotive Segment FlexLink, Sweden

Dr. Gábor Bohács Head of Department at Budapest University of Technology and Economics in Hungary, specializing in Lean Management.

My name is Sven-Erik Eckerström and I started working at FlexLink in Sweden, in 1987. I work as Product Manager for the Automotive area, and my focus areas are automation in automotive and bearings. In my job, I enjoy solving complex problems when it comes to production flows and processes based on logics. When I am not working, I like to spend time on the ocean where I enjoy fishing and boating.

Balázs Sztrapkovics Engineer, also specializing in Lean Management. Balázs Sztrapkovics and Dr. Gábor Bohács has done a successful collaboration with FlexLink, assisting them in the implementation of Lean in their automated production flow solutions.