Matthew Riddle, KLEENLine Robotics Engineering Designer has almost a decade of robotics experience in various industries, including Automotive and Food and Beverage. He holds a BS in Mechanical Engineering degree from the University of Kentucky.
When tasked with innovating better automation solutions, we too often knock ourselves out following very logical, oh-so-sequential thought pathways. We’re engineers and production automation experts. So this comes naturally, by training and it’s based on scientific principles. Sometimes, however, we find our “eureka” moment when we allow ourselves some “off-the-wall” thinking time — this is called
“lateral thinking.” We’ve all had these moments, some more than others. They’re always fun, not always productive, but sometimes give us a “break-through
” solution that dramatically improves how we do things. And, they permanently change our thinking and approach to finding solutions — for the better.
Here at KLEENLine, we’re in the automation solutions business. We succeed because we have deep and broad technical expertise and experience — engineering, fabrication, robotics, programming, systems simulation, among others. And, we follow time tested and proven automation goal strategies — the principles of Lean Manufacturing for example. But, we also succeed because we encourage creative, “lateral thinking” when it comes systems design. Sanitary manufacturing, our core strength, gives us the opportunity to lead the convergence of lean manufacturing concepts with the best of robotics automation for our end-users. While robotics initially entered the sanitary manufacturing world cautiously (SLOWLY), the pace is accelerating. So is the success rate for substantial, incremental lean manufacturing improvements driven by robotics.
What often gets us from the basics of lean manufacturing to a robotics solution is lateral thinking about the basics:
- Designing systems means simplifying
- Everything can always be improved
- Creativity can enhance lean manufacturing systems design
So that’s how we approach the seven principles of lean manufacturing:
- Transporting
- Inventory
- Motion
- Waiting
- Over Production
- Over Processing
- Defects
Over the past several years, we’ve helped many of our end-users make substantial improvements in one of these areas with the integration of a robotics solution. We’ve proven that robotics can improve both production operations and bottom line business performance a number of ways. We know this positive trend will continue to accelerate and that’s a very good thing. We’d like to share some good reasons for integrating robotics into lean manufacturing strategies and goals. While ABB Robotics communicated these points in a white paper, we’ve proven them in projects we’ve designed and integrated for many end-users over the past years. They’re based on research from the International Federation of Robotics (IFR). Here’s how creative thinking about robotics — with some recent real world examples from KLEENLine projects — can help deliver the benefits of lean manufacturing:
1. Reduce Operating Costs — Robots are cheaper to operate than manual intervention. Energy savings can be significant due to lowered heating requirements in automated operations.
2. Improve Product Quality and Consistency — Accuracy and repeatability.
3. Improve Employee Work Environment — Robots can take over tasks that are hazardous for humans, freeing employees up for higher-level assignments.
KLEENLine is currently replacing a large palletizing cell for a major confectionary manufacturer with a robotic palletizing solution, saving operators from the strain and injury that result from continuous bending and lifting.
4. Increase Production Output - Robots can run for long shifts, overnight, and during weekends with little supervision enabling true 24-hour production runs.
Another KLEENLine customer is running three full, high-production shifts with robotic case packers. Operators just ensure empty cases are in the line. The robotics do everything else.
5. Increase Product Manufacturing Flexibility — Systems with robotic automation can accommodate variations in product and process mixes resulting in maximum ROI on capital investment. Also, vision systems for robots have greatly increased the flexibility of robot usage.
Robots integrated by KLEENLine excel at flexible operation. Palletizers switch seamlessly from case patterns and sizes on demand. And, vision-guided robots at a large frozen food customer facility, easily alternate picking sandwiches and frozen pizzas with just the flip of a switch.
6. Reduce Material Waste And Increase Yield — Robots perform routine functions to fine tolerances, reducing rejects and scrap waste.
7. Better Safety Rule Compliance And Improved Workplace Health/Safety — Robots can take over tasks in conditions that are hazardous to human workers. Robots can also handle tasks that if done manually, could lead to ailments such as repetitive strain injuries (RSI) or vibration white finger. Welding environments are inherently hazardous for human eyes; this safety issue can be avoided by using robots.
Case packing robots at an energy snack facility in Indiana have significantly reduced operator repetitive motions and lifting heavy full cases. Reducing continuous repetitive motions reduces boredom and injuries that result from inattentiveness.
8. Reduce Employee Turnover And Improve Recruiting — Running a manufacturing plant with automation requires a technically skilled workforce. The work is challenging and the associated problem-solving requirements make the tasks intellectually stimulating. Consequently, employee turnover is reduced and the Company attracts high quality employee candidates.
Many KLEENLine customers are taking advantage of robotics to also free up skilled employees for higher level, more rewarding assignments.
9. Reduce Capital Costs (Inventory/ WIP) — ROI from robots is quicker than manufacturing with operators. Robots can be programmed to produce products on a just-in-time basis thereby reducing the amount of inventory or work in progress.
10. Save Space In High Value Manufacturing Areas — Robots can be mounted on walls, ceilings, rail tracks and shelves as well as firmly mounted to the floor.
Palletizing robots can service several lines at once. A four line robotic palletizer can replace four large, expensive, conventional palletizing machines, saving valuable floor space by combining all that activity into one cell. One KLEENLine customer — a candy manufacturer is severely floor-space challenged. Integrating flexible robots is enabling them to stack pallets in a room with 10 ft ceilings and a very small footprint.
Try some lateral thinking and talk to us today about how robotics can help you improve operations and business performance.
Kevin Tappa — KLEENLine’s Applications Engineer, has 30 years experience managing food and beverage manufacturing plants, improving production performance and providing automation engineering expertise for a widely diverse range of products across the entire US geography.
The current daily upward march in the price of gasoline, while difficult for all of us, does have its redeeming value. It forces us to get serious, to ask questions about our energy future. And importantly, it gets us focused on the broader question — are we working together and are we working hard enough to — build a sustainable environment. And it raises the question of where in society are we finding the expertise, the initiatives and the realistic goal-setting to achieve sustainability.
If you follow our blogs, it comes as no surprise that we at KLEENLine believe the leading sector in championing sustainability is US Manufacturing. There are good business reasons why in addition to the overriding responsibility to be good corporate citizens.
Manufacturing operations are by nature:
- Energy intensive
- Raw material intensive
- Waste generators
- Water consumers
- Transportation dependent
What this means is that, in the manufacturing sector, the opportunities to positively impact sustainability are huge. In fact, manufacturing can rightfully call itself the sustainability precursor sector. Processes, technologies and equipment innovations developed to improve manufacturing energy efficiency, soon find their way into the other components of our economy.
Major manufacturers are committing in writing to goals for eco-sustainability and are continually achieving new levels of energy efficiency performance. They are being more than altruistic. Sustainability progress shows up on the bottom line. After all, eco-conservation is part of the driving motivation for automation innovation;
- Reduce energy costs while producing more
- Reduce waste while increasing quality and yield
- Reduce water consumption while improving sanitary performance
So, focusing on processes, technologies and equipment that further these goals can be an important strategy for success. Reduced electric energy consumption can dramatically reduce operating costs, as can reduced waste that needs to be transported and disposed of or reclaimed. Reducing water consumption lowers the cost of acquiring it and the costs associated with sanitizing it for disposal or recycling it.
As total solution integrators, we at KLEENLine are fully committed to best designs and best fabrication for our end-users’ operations. And we’re equally committed to integrating solutions developed by others in the broad manufacturing partnership. Progress in manufacturing comes from sharing ideas, innovations and values among equipment providers, technology developers, integrators and end-users. Fortunately it’s a long-standing modus operandi in the manufacturing world.
Case Study
One of our recent projects is a case in point. The customer, an internationally recognized, successful food and beverage manufacturer is making major upgrades to its material handling automation capabilities. Aggressive energy conservation is a primary requirement. So, we designed in and integrated two innovative, energy-smart technologies from Interroll.
The Interroll 480VAC Drum Motor achieves its dramatic results because of its high output transfer of up to 97%. This is possible because no power is lost through shafts, sprockets or chains required with gear motors. Other key benefits of Drum Motors include space efficiencies, safety and ease of maintenance.
24VDC Zero Pressure Accumulation Conveyors deliver substantial energy savings because the conveyors only run when a carton is in a given zone. At all other times, the conveyors turn off. This drives substantial energy savings and significantly extends the life of the equipment. As an added benefit Interroll 24VDC conveyors run at under 68Dba providing dramatic noise reduction.
For more industry insights into energy conservation, take a look at these 4 ABB reports.
When you need better understanding of energy issues and how they impact your production operations, give us a call. We’ll be glad to share our experience and expertise about eco-friendly automation. And we’ll show you how to improve production performance so that it helps put pluses on the bottom line.
Jim Laverdiere, Vice President and General Manager for KLEENLine. As founder of KLEENLine, Jim has lead the company to industry leadership in sanitary conveyor solutions throughout its successful 25 year history. He continues to manage KLEENLine Operations going forward in the family of Pro Mach companies.
M. Dinne Flansbury, KLEENLine’s Director of Engineering has over 20 years of hands-on and management experience in all aspects of manufacturing engineering — including new product development, process design, strategic planning and supply chain development. His industry experience spans the food and beverage, bio-pharmaceutical, electronics, medical, aerospace and automotive sectors.
The President, in his Fiscal Year 2013 budget, expressed support for creating a National Network of Manufacturing Innovation (NNMI) saying, “American workers have the drive, the creative thinking, and the determination to out-innovate the rest of the world.” He also prominently mentioned this manufacturing focused initiative in his 2013 Sate of the Union message.
Manufacturers, automation integrators, technology developers, equipment providers, career educators, software developers, industry institutions and now politicians are all singing from the same song sheet. There’s an economic tsunami building and it’s powered by US Manufacturing strength. From previous blogs, you know where we stand. KLEENLine will continue to enthusiastically promote all the converging forces for advancing smart automation strategies and practices — especially initiatives like NNMI. And, we plan to continue driving innovation in our arena of integrated sanitary manufacturing.
The reasons are paramount:
- Consumers deserve safe, desirable products that are also cost smart
- Sanitary manufacturers need the technology, equipment and processes that will help them deliver on customer promises and help drive their own business success
- The US economy needs the competitive advantages and quality jobs that a resurgent manufacturing sector is driving
As a premium automation solutions provider, we see our role at KLEENLine as:
- Continuing to design, build, install and support the highest quality sanitary conveyors in the industry
- Integrating our solutions with innovative technologies, equipment, robotics and standards to drive production, quality, safety, maintenance and cost reduction improvements for our end-user customers
- Partnering with other automation solutions providers in the Pro Mach family and with technology solutions providers across the manufacturing world
- Communicating frequently with customers and other automation stakeholders –– valuable information based on our over a quarter century of expertise and experience contributing to production advancements
Give us a call today. We’d love to share our knowledge about automation technology and how it drives business success. We’ve been doing this a long time and we know from experience what works and why. We also have a very focused view of what’s on the near and far horizons for automation innovation. And we’re playing a very active role in developing some of that innovation.
Matthew Riddle, KLEENLine Robotics Engineering Designer has almost a decade of robotics experience in various industries, including Automotive and Food and Beverage. He holds a BS in Mechanical Engineering degree from the University of Kentucky.
We’ve talked a lot about transformative technologies, processes and equipment and how they benefit sanitary manufacturing. It’s like a decathlon performance.
At KLEENLine, we’re big believers in solutions that deliver 10 essential qualities:
- Streamline automation processes
- Make people and products safer
- Increase quality and throughput simultaneously
- Build flexibility into the production system
- Help balance technology driven performance improvements, manual labor requirements and business growth
- Reduce maintenance and contamination challenges
- Ensure repeatable accuracy
- Improve quality and reduce waste
- Operate with low downtime over long periods
- Enable easy and complete washdown
Our viewpoint has always been big picture. We design, build, install and support completely integrated sanitary conveyor automation systems. It’s no secret that we’re knowledgeable and enthusiastic advocates of robotics in processing, packaging and palletizing operations.
After proving themselves in the automotive industry, robots moved, slowly at first, into other industries — including food and beverage. According to PMMI (Packaging Manufacturers Machinery Institute), sanitary manufacturers and packagers resisted bringing robotics into production lines because of perceived, high initial investment. Over time, however, the packaging function has benefitted significantly from robotics. Cost savings began to outweigh the high initial cost concern. And other advantages, we mentioned above, are now emerging as strong additional incentives for improving operations with robotics. In fact, the integration of robotics into packaging line functions is accelerating dramatically. From about 10% penetration in 2003 to around 18% in 2008, we now see that 35% to 40% of packaging operations depend on some form of robotics for performance improvements.
“We are always looking at efficiency, uptime and quality.”
“We look at the same measures we use for all equipment — time, efficiency, cost to maintain.”
“It’s not always about payback, Many times the robot is the
only equipment that can get the job done.”
PMMI survey feedback from companies using robotics was very high. 80% of packaging line operators using robotics rated them as “very important” or “extremely important” to the success of their packaging operations. Among all food companies using robots, the “very important” response was also 50%. Typical comments of production line managers proved telling about what they liked:
Case Study
Perhaps a good way to make a point about the value of robotics is to walk you through a quick anatomy of a recent KLEENLine robotics integration project.
A very large customer with an internationally well-known line of confectionary products planned major improvements to packaging lines in one of their US plants. We are integrating the flow of various product carton sizes with different weights over four different lines with multiple conveyor types. The flow moves from production areas through walls, over lines and up through ceilings into a palletizing operation.
The challenge included:
- A broad range of package sizes changing frequently
- The need to pick sometimes three or four cases simultaneously
- The need to reduce the need for manual intervention
The KLEENLine solution for the production line included:
- Plant layout, controls, robotics, integration and installation
- Two FANUC M410 robotic palletizers for picking cases and pallets
- Manage four lanes per robot
- Design integrated and programmed for handling overlapping case sizes
- Manage at least four incoming lines simultaneously
- Ability to handle 45 to 50 cases per minute per robot
- Reduce dependence on manual intervention by a factor of eight to 10
- Link production flow to T-Carts and then to shrink-wrap operations
The results include:
- Easy and flexible product switching
- Greatly increased throughput
- Reduced manual intervention goals met
This project also underscores a quick lesson from last week’s blog — the importance of accurate information input related to product dimensions, weights, etc and other line flow parameters. In this case, accurate product dimensions and plant floor drawings helped keep the project on target. Often, that is not the case and outdated floor plan drawings can result in delays and design errors.
So if you’re thinking about robotics or facing production challenges that have you scratching your head, give us a call. We’ll be glad to share our experience and expertise with you.
Kevin Tappa—KLEENLine’s Applications Engineer, has 30 years experience managing food and beverage manufacturing plants, improving production performance and providing automation engineering expertise for a widely diverse range of products across the entire US geography.
Most of us would agree — when we’re in familiar settings we put decision making on autopilot, paying less attention to details. It’s when something is new to us that we decide to pay attention, ask questions, look for proof and take great care in making decisions. In familiar situations, we trust, we assume and we act on instinct or “gut” feelings. History is littered with the “trains wrecks” of assuming based on familiarity. Remember typewriters, 8 track cassettes, music CDs, pay phones, telephone books, passenger rail service and film cameras. A lot of time, planning and money went into keeping these icons of 20
th century life relevant and profitable. But the Zephyr of 21
stcentury living left them in the dust.
The lesson hopefully learned — pay attention to detail when planning for change, even if you think you know the territory inside and out. When it comes to planning and implementing production line automation improvements, manufacturing managers are in very familiar waters. So, all the more reason to focus on detail, to avoid assumptions and to think well past the point of project completion.
At KLEENLine, over our 25-year plus history, we’ve successfully completed thousands of integrated conveyor line projects. They encompass virtually every conceivable configuration, technical challenge, budget restriction and time deadline. That gives us a vast experience base of what works well for manufacturers in completing their projects on time, on budget, and on target for operational success.
As you ramp up for your next automation project, make these guidelines part of your methodology. They can help you hit your operational and business objectives.
| 1.Balance current production needs with future business goals. As is often the case, especially with contract manufacturing, the decision to invest capital in new production capacity is weighed against one or two year production goals for a specific product. That thinking can make ROI more difficult to achieve and can limit solutions to one or two years of business contribution. Before deciding on an automation solution talk to Sales/Marketing and company business planners about what opportunities they see coming. Factor this into your requirements development and ask a smart integrator for insight about the best solution for your business model.
2. Double-check the accuracy of specs before handing them over to your integrator. Little differences can have a big impact. A dimensional error of as little as a ½ inch can mean a world of difference to an end-of-arm robotic tool. Make a “flight plan” level checklist. Consider all aspects of:
- counts
- weights
- rates
- speeds
- elevations
- dimensions
- materials properties
- product and people safety concerns
- maintenance and washdown issues
If everything isn’t included and triple checked for accuracy, you’re not ready for take off.
3. When you put together your project management team, keep in mind that your choices hold the keys to project success or failure. Get the right mix of skills on the team. Make sure that all team members bring not only technical skills but also:
- positive attitude about change
- time available for team involvement
- true commitment to success.
Partially involved participants can quickly move your project off course, off budget and out of time.
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4.Make team communications a top priority. Hold regularly scheduled meetings. Expect 100% attendance. Keep meticulous minutes and communicate them in real time to team members and to all employees who will have a role in the project. Encourage constructive feedback.
5. Keep an open mind about technology — even emerging technology. You won’t fail for considering how it might improve operations and business performance. Your automation integrator can be a great source of ideas and information about what different technologies can deliver, and more importantly, if they make sense for your production environment and business goals.
6. Business considerations need to have equal weight with production goals. Before you ramp a project up make sure you thoroughly understand your Company’s ROI goals for capital investments. For example, is it long ROI (after tax) or short ROI (before tax)? In our experience, less than two years is smart. 12 to 18 months is a clearance for takeoff. We recognize, however that for some business reasons, longer ROIs of 3 to 4 or more years make sense. Taking a rapidly growing product national, new product development for a high potential product, industries with products requiring expensive capital equipment may all do well with longer ROIs. But the point is –– know your company’s financial structure. Also, keep in mind that you’re balancing labor needs with business sustainability. Smart project planning and implementation can help you achieve the optimum balance.
7. Put integrator experience, success track record and range of expertise on your team strengths chart. The right conveyor integrator will help get you to your destination on time, on budget and on target with your objectives. That means your line will be contributing cost reduction, quality improvement, safety advantages, production quotas and profit.
8. Dig into your conveyor integrator’s support record. If they have developed a true “customer first” culture, they’ll be delighted to answer questions, have you meet team members, talk to other customers and walk you through their methodology.
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At KLEENLine, we’re always ready and open to discussing how you can improve project outcomes and get ahead of objectives.
Jim Laverdiere, Vice President and General Manager for KLEENLine. As founder of KLEENLine, Jim has lead the company to industry leadership in sanitary conveyor solutions throughout its successful 25 year history. He continues to manage KLEENLine Operations going forward in the family of Pro Mach companies.
Broader scope, faster pace, smarter technology, increased flexibility are all part of the mix. And KLEENLine — now part of automation leader Pro Mach’s Integrated Packaging Solutions — is helping transform manufacturing automation with innovation and complete, integrated solutions.
Sanitary manufacturing — especially food, beverage and pharmaceutical — can probably lay claim to the title of “world’s most dynamic manufacturing sector” for many reasons:
- Largest product consumer base — 6 billion plus
- Product importance — essential for life
- Vast, complex value chain — agriculture, chemical, biological, manufacturing, packaging, warehousing, transportation
- Technology rich — electrical/electronic/mechanical/robotic/data management
- Longest product history of improvement — efficiency, quality, product diversity, packaging, distribution
- Consumer knowledge and influence — dietary health, prepared meals, price awareness, green packaging, shelf life, public medical databases and interest groups
- Strong tradition of goal and solutions sharing among automation integrators, equipment manufacturers, robotics suppliers and end-users.
Over the next weeks, we’ll visit topics related to Pro Mach strengths in primary packaging, end-of-line packaging, identification and tracking. Pro Mach provides individual products and solutions as well as complete integrated systems from a wide range of equipment and components designed and manufactured by the Company’s 20 brands — each a leader in their market segment. And we’ll discuss how these capabilities integrate with KLEENLine strengths to broaden the solutions we provide sanitary manufacturing end-users. As part of this blog tour, we‘ll look at sanitary automation trends and issues, related KLEENLine experience and capabilities as well as the experience and added resources of other Pro Mach brands.
We believe that the pace of automation transformation is accelerating rapidly, driven by:
- Rapidly escalating product and packaging diversity, especially in food and beverage
- Sweeping new FDA regulations (Food Safety Modernization Act - FSMA) and reporting compliance rules
- Bottom-line business need for more seamless integration of production and machine performance data with legacy and “cloud” (SaaS) ERP systems
- The need to build optimum flexibility into manufacturing operations
So, let’s start our review of strengths versus challenges with a quick look at how food safety is impacting how manufacturers manage for success. KLEENLine, over the past 25 plus years, has earned a reputation as a premier sanitary automation solutions provider. Our fully integrated conveyor systems are designed for maximum efficiency, effectiveness, safety, fewest “touches” and enhanced technology advantages. And, they are built for long length-of-service, low downtime, simple maintenance, optimum flexibility and easy wash-down.
Consider that a single food product may contain 30 to 50 globally sourced ingredients from hundreds of individual suppliers and you can appreciate the challenge of maintaining high product safety standards as well as meeting FSMA compliance reporting rules. Now, with the added strengths of other Pro Mach brands, such as ID Technology, KLEENLine will be able to seamlessly integrate product id and tracking capabilities into our conveyor solutions. This helps immeasurably in tracing sources and destinations — critical to building business controls and reporting capability. One more reason why KLEENLine will stay out front in product quality innovation.
On another front, we have spent the past year promoting the Pack ML standard for machine communications. This smart technology standard:
- Gives manufacturers better real-time control over line processes,
- Shows operators a common, easy user interface
- Builds seamless data bridges from production processes directly into ERP systems and across all departments
The bottom-line for implementing Pack ML is easy to understand:
- Faster, more flexible management decision-making
- Lower costs
- Less waste, higher yields
- Better response to change
- Improved margins
If you’re ready to discuss the near future of automation and how you can improve operations, give us a call. We’ll be glad to share our knowledge and experience as well as cover other Pro Mach resources.
M. Dinne Flansbury, KLEENLine’s Director of Engineering has over 20 years of hands-on and management experience in all aspects of manufacturing engineering — including new product development, process design, strategic planning and supply chain development. His industry experience spans the food and beverage, bio-pharmaceutical, electronics, medical, aerospace and automotive sectors.
Kevin Tappa—KLEENLine’s Applications Engineer, has 30 years experience managing food and beverage manufacturing plants, improving production performance and providing automation engineering expertise for a widely diverse range of products across the entire US geography.
The ink has hardly dried on 2012 results, but we’re already in fourth gear driving toward 2013 goals. Our world — sanitary manufacturing — presents us with a constantly, fast-changing landscape. We have to successfully maneuver past conditions that could stop us short of goals. They include:
- Rapid or unforeseen product changes in response to marketplace dynamics
- Sudden increases in production quotas
- FDA and OSHA safety directives
- Raw material shortages or price increases
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- Unplanned downtime
- Increased waste or reduced yields
- Spikes in energy costs
- Ineffective integration of production data flow with business planning systems
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But, we keep in mind that every challenge we beat installs a permanent improvement in production operations. With that said, let’s look at a couple of high payoff technology advances that can make driving through 2013 and beyond, more energy efficient, more operationally effective and — bottom line — more profitable.
At KLEENLine, we’re showing customers how to take advantage of an emerging technology called Actuator Sensor-Interface or AS-i as it’s commonly called. AS-i is a simple wire reduction system that makes it easy to replace point-to-point wiring while complementing higher-level bus systems. Think of it as a highly efficient and effective network. It not only reduces wiring, but it also eliminates termination points. How does AS-i accomplish this? Basically it connects inputs and outputs through a single, two-wire flat cable. Best of all, it’s very easy to install and commission.
We’ve all cringed at installing separate lines for every data bit and then more lines for power. AS-i dramatically reduces all that wire while also reducing communications errors. Obviously, this type of wiring improvement can help reduce energy costs as well.
And here’s the bottom line for end-users. AS-i can cut overall machine costs 50% by reducing:
- Wiring labor costs
- Wire labeling costs
- Machine assemble labor costs
- Machine testing labor costs
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- Machine disassembling costs
- Shipping costs
- On-site commissioning labor costs
- Maintenance costs while making troubleshooting easier
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The good news doesn’t stop there. AS-i also has benefits for equipment providers. It means:
- Less engineering time
- Reduced BOM costs
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- Eaiser troubleshooting and commissioning
- No additional software required
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Now, let’s move to another automation advancement we believe has major positive implications for the packing phase of manufacturing. We’ve talked about Pack ML in previous blogs. But we can’t say enough good about this long wished for standard. The primary objective of Pack ML is to bring a common “look and feel” and operational consistency to all machines that make up a Packing Line. Importantly, it can be used for other types of discrete processes as well.
There are lots of benefits. For example, at the very basic level it makes life easier for operators who now get a standard look and feel at all stations. Best of all, it enables and encourages industry innovation on many fronts. One of the reasons Pack ML holds so much promise is that it’s a shared effort among Control Providers, OEMs and End-users. That’s a pretty broad swath of the packing world. It’s why we believe shared improvement efforts always result in more significant payoff for our industry.
But perhaps the greatest long-range benefit of Pack ML development is the transformational potential it offers for computer integrated manufacturing management. By facilitating links among all points in the packing line and with the MRP and ERP systems, Pack ML will help create a more seamless planning and management environment. This in turn, will help manufacturers cut costs, improve quality and safety, better serve customers and grow profit margins.
Talk to us about AS-i and Pack ML and other important trends you see coming. We’ll be glad to share our experience and knowledge about the road to the future.
M. Dinne Flansbury, KLEENLine’s Director of Engineering has over 20 years of hands-on and management experience in all aspects of manufacturing engineering — including new product development, process design, strategic planning and supply chain development. His industry experience spans the food and beverage, bio-pharmaceutical, electronics, medical, aerospace and automotive sectors.
Kevin Tappa—KLEENLine’s Applications Engineer, has 30 years experience managing food and beverage manufacturing plants, improving production performance and providing automation engineering expertise for a widely diverse range of products across the entire US geography.
What better time to look ahead than at the very beginning of the New Year. Our sense is that 2013 portends more good news for US manufacturing. Why? Well, we’ve talked over the past year about US leadership in productivity advances as the basis for our sustained manufacturing resurgence. And we’ve highlighted innovation as our principal enabling quality. Here at
KLEENLine, it’s something we think about a lot. Innovation is why we succeed as a premium conveyor solutions integrator. So, it’s fitting that we start off the New Year with our “blue sky’ view of where to look for the innovation automation technology that is fast approaching. Our advice — there’s no better time to embrace it than now.
It’s also important to note that manufacturing innovation is driven by more than the need for increased productivity. Other key motivators include:
- Product and employee safety
- Rapid new product development
And, next week we’ll look two other motivators:
- Energy efficiency goals
- Opportunities for improving profit margins
We’re not clairvoyant, but we pay attention to what’s going on in our industry and what’s approaching to help us all build an even better future. For us, “all” includes sanitary conveyor integrators, equipment and logic providers, technology and materials developers, standards and process innovators, end-users and industry advocates. Together, we ‘re the team keeping US manufacturing in the global leadership position. With that in mind, here are some of the many emerging elements that we track, with a mind to implementing for the benefit of our customers and their customers.
Product and Employee Safety
In our world of sanitary automation, we are driven to keep products and people safe throughout the production process. So we look at designing in new and improved materials to build our systems. For example, alternative polymers for belts can make a big difference. They can withstand the rigors of temperature, pressure and caustic chemicals required for ultra-sanitary equipment washdown. So, it’s important to look ahead for advanced materials and technologies (see our blog on Hyperspectral Imaging) for safety solutions and then adopt early.
At KLEENLine, we want to help ensure that automation environments can deliver high quality, completely safe product to the consuming public. So, in addition to materials and technology, we look carefully at the washdown properties of the equipment and robotics we integrate and work with our partners on improvements. Additionally, over the past year, stringent, new FDA directives (link to article) have mandated that food and pharmaceutical manufacturers take broad new steps to ensure a safe product supply. The answers lies in embracing new materials, new designs and new process systems and software (see our Pack ML blog) approaches as early as possible.
Rapid New Product Development
The food and beverage marketplace rivals consumer electronics for the rapid pace of new product introductions. This is driven by an insatiable marketplace demand for tastier, healthier, “easier-to-prepare” products in always better packaging. That’s a tall order and it puts a lot of pressure on manufacturers to focus on the flexibility, speed and yield of their production systems. Here, premium integrators help by designing in and building integrated conveyor solutions that incorporate innovative approaches to flexible automation like smart sensor technologies many with “plug and play” capabilities as well as improved controller logic.
Also, these same integrators are designing and building conveyors with new belting systems that improve product orientation, increase speed and help ensure right product counts for packaging. Integrators are also working closely with robotics developers to rapidly advance the efficacy of robotic systems in helping achieve aggressive production goals and bottom line objectives. We’ll also talk more about that in next week’s blog.
In the meantime, give us your thoughts about emerging technologies you feel are important. Or, just call us (800-259-5973 or 978-463-0827) for more detail on what we see on the automation horizon.
Jim Surette, KLEENLine Operations Manager
Three decades of experience as a contributor and manufacturing manager of conveyor and production equipment for the food, beverage and pharmaceutical industries. Jim also designs conveyor safety enhancements that are implemented in the manufacturing process.
Matthew Riddle, KLEENLine Robotics Engineering Designer has almost a decade of robotics experience in various industries, including Automotive and Food and Beverage. He holds a BS in Mechanical Engineering degree from the University of Kentucky.
As an introduction to our second installment on innovation, we’ll add another piece of good news to our continuing focus on US manufacturing strength. Steel manufacturing is starting to return to US shores in a building crescendo. What’s behind this resurgence is mostly innovation leading to competitive advantage and real bottom line payoff. What was innovated? First, a better process for the first stage of steel production called direct-reduced iron production now makes it an easy decision to manufacture steel here. Second, this process can use natural gas instead of the coal required in the coking method of steel production.
That gives the US a natural competitive advantage. Why? Because US engineers have developed smart new technology for extracting gas from shale. That has resulted in greatly increased supplies of gas, lower energy prices and consequently much lower production costs for steel manufacturers. If that isn’t reason enough, consider that natural gas in much cleaner burning than coal and is also more energy efficient. So instead of continuing in decline, steel producers innovated and are resurging in the US.
Innovation is something we all think we do well. But creating something new — an idea, a method or a device — doesn’t always mean creating something useful. Over the past 30 years or so the word ”innovation” has joined business lexicon as a term for something better. Let’s hope that overuse doesn’t relegate the term to the business jargon dustbin along with the likes of empower – drinking the Kool-Aid – thinking outside the box – it is what it is – synergize — and in the case of innovation — bleeding edge.
In our world of sanitary automation, innovation must carry real meaning. It must drive measurable improvements in both operational performance and business results. As part of our internal template for innovating at KLEENLine, we ask ourselves key questions. When we can answer those questions, we know that we’ve got our sights correctly set on productive innovation. Here are just a few of the questions we ask:
- How can we move product faster?
- How can we better keep proper product orientation through out all line stages?
- How do we improve product and people safety?
- How can we make best use of floor space?
- How do we take complexity out processes?
- How do we simplify equipment design?
- How do we increase equipment reliability and life span?
- How do we design and build products that withstand the rigors of intense washdown?
So who answers the questions? At KLEENLine it’s every employee. Engineers draw on 25 years of experience designing and integrating premium automation solutions a wide range of sanitary manufacturers. Fabrication specialists answer the questions about the best way to build successful designs. Installation team members provide first hand knowledge of what will work best in a specific environment. We certainly recognize the brilliance of the Henry Fords and Thomas Edisons of the world. But, we know that most great innovation today works best when multiple technologies and specialties come together to drive total integrated solutions — especially for production lines.
In our blog before the holidays we promised innovation examples from are Integration and Fabrication specialists.
Fabrication
When a customer requested more spacing between products for easier and more accurate product counting, KLEENLine Fabrication specialists came up with a unique solution. Better yet they delivered the new system in just two business days. With install team members, they took two existing single speed conveyors out of line. They then reworked them, creating thee motor speed up conveyors with individual belts. Best of all they kept the same size footprint to meet the customer’s space restrictions. The new solution gave them the accurate count capability they needed. All this happened in a two-day turnaround from rip-out, engineering, manufacturing and install to get the customer up and running.
Integration
When a customer came to us with problem picking frozen trays, KLEENLine Integration engineers isolated the problem to the trays lids not securing well enough for proper pick up. The solution was a custom innovation for the robotic vacuum end-of arm tool that pushed down on the lid and increased the traction of the gripper. Problem solved, production back on track.
We’d love to share our thoughts with you about innovation, hear your ideas and talk to you about how our innovators can deliver solutions you need.
Jim Laverdiere, Vice President and General Manager for KLEENLine. As founder of KLEENLine, Jim has lead the company to industry leadership in sanitary conveyor solutions throughout its successful 25 year history. He continues to manage KLEENLine Operations going forward in the family of Pro Mach companies.
This week, every year without question, encourages all of us to reflect on the most important aspects of our lives –– family, friends, career teammates, professional contributions, and business accomplishments. At KLEENLine, as we look back over the year, we are especially thankful for:
- The very productive cohesiveness of our engineering, fabrication, installation, support and operations employees
- Our recent integration into the Pro Mach family of automation solutions providers
- Close relationships with our automation technology and equipment partners
- Our customers who share with us in the development of “industry best” production solutions
- End-user customers who help nurture the creative spirit that drive all of us who make US Manufacturing the number one productivity engine on the planet
- Manufacturing industry associations and trade press organizations who help keep all of us informed of issues and developments and ahead of the state-of-the-art
To all — Happy Holidays and Success in the year to come.
Jim Laverdiere and the KLEENLine Management Team