INDUSTRY SOLUTION PACKAGE SORTATION AND PLACEMENT DEFINITION Pick components or products and place them in the appropriate compartment with the correct orientation as well as provide sortation functionality in conjunction with vision
Package Sortation and Placement Primary Packaging
Confidential Secondary Packaging
Confidential Target Customers Processors / Packagers Make products which enrich lives Customers like Proctor & Gamble, Bimbo Bakeries, Kraft (Oscar Machine Builders Meyer), Mondelez, EOS Make machines for manufacturing Customers like Ulma Packaging, Components Suppliers Xigent Automation, Big Sky, Winpak Lane Provide components to support processors / packagers Customers like Phoenix Closures, NAICS Phoenix Packaging, Pactiv, Dolco SFDC classification for the industry 311 Food Manufacturing Packaging Category 312 Beverage Manufacturing
Products or equipment supplied to the industry categories Categories like primary and secondary
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What is Package Sortation and Placement?
In an age of rapid industrialization and intense competition, processors and packagers are looking for more speed and accuracy of the machines and assembly lines in their production units. They are now investing in technologies that speed up the functions on the assembly line front and also add to the precision of operations. Herein stems the importance of pick and place robots in an assembly process. These systems are commonly found in industrial automation processes and are used to sort components and place them in their appropriate slots in the line. Intended application: • Primary handling – putting individual pieces or components into a tray or carton • Ready Meals • Confectionery • Beverages • Cosmetics • CPG • Pharmaceutical
Confidential Why is Package Sortation and Placement so Important?
Package Sortation and Placement is critical because it: • Speeds automation processes, which leads to faster production • Offers precision in operations, compensating for errors caused by human intervention • Offers reliable operation performing repetitive tasks with virtually no downtime • Allows for flexibility to handle differences in pack size and product change- overs • Ensures product components are placed in the proper tray compartments for mixed-variety packs • Keeps food safe from pathogens during direct contact, such as blood, perspiration, tears, etc.
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By 2018, robotic integration in the food and beverage sector is expected to grow by 144% (PMMI) 01
26% of end-users worldwide have 02 implemented parallel-style robots on their packaging lines (PMMI)
The main driver behind the growing implementation of robots in primary packaging is the increasing demand for 03 more varied packaging, pack counts and retail-ready packaging PMMI states that the greatest potential for robot 04 integration is in the dairy industry Quality Improvement: Guarantee product placement, orientation and defect inspection Cost Reduction: Increase productivity by automating repetitive, labor-intensive tasks Increased Throughput: Handle multiple applications on a single line with minimal disruption to existing processes Repeatability of Product Placement: Handle tedious and monotonous tasks with 100% repeatability and accuracy in a 24/7 environment Flexibility: Quickly perform change-overs with minimal downtime to accommodate changes in product requirements
Current Situation – Sortation and Placement
Variety packs with different color components slow production and create waste because grayscale vision incorrectly picks and places components
Incorrect sorting due to grayscale vision
Challenges / Issues Implications • Vision system incorrectly identifies • Increased waste due to incorrect products due to grayscale vision sorting based on color differences • Hard for the system to keep up with • Recall liability due to the inability production due to manual to pack products according to label intervention specifications • Low productivity due to the lack of • Decreased throughput because of communication between the robot the need for manual intervention for and the vision system color sorting
Omron’s Solution – Sortation and Placement
The FH and Omron Adept Hornet robot are capable of high speed sorting and pick and place with color recognition and 360°rotation
Hornet Parallel Robot FH Vision System NJ501 Machine Controller
Highlights Implications • High-speed FH vision system can • Increase throughput due to speed sort product by color of communication among • Up to 8 cameras for multi-lane machinery inspection and sorting • Eliminate waste through 100% • Hornet parallel robots pick and sortation accuracy place with high speed and high • Eliminate recalls with accurate and accuracy reliable pick and place functionality Implementation – Sortation and Placement
NJ501 NX I/O NA HMI
To Cartoner FH Vision
Arrival of Products
Highlights Featured Products NJ501 • NJ501 is a scalable machine controller that can handle multiple functionalities FH series • FH vision system offers color recognition Hornet parallel robots for higher speed production and can NA HMI easily integrate up to 8 cameras NX I/O • Advanced diagnostics with the NA HMI • High-speed system with Hornet parallel robots synchronized across the entire line
Results: Pepper Packaging Company
• Throughput has increased by 5% due to the FH’s ability to detect and filter products with low integrity in 360° orientation • The FH vision system guides the Hornet parallel robot to pick different color products, aligning them in the correct color order, eliminating manual intervention • Easy-to-integrate robotic FBs with the FH vision system, allowing them to place different color peppers in the correct order for flow wrapping preparation • Customer was able to easily switch between product packages – from a variety pack to a singular color pack - using recipe selection functionality via one-touch on the NA HMI as supported by the NJ
UNLEASH YOUR KNOWLEDGE Protects unpackaged food from damage, protecting brand image and product integrity Protects food from human contamination reducing the potential for food safety issues Handles repetitive motion over long duration which decreases ergonomic issues associated with manual labor Automates processes that involve a fast-moving conveyor, eliminating manual errors Less waste/scrap due to high precision and reliability Visual inspection keeps non-conforming products from moving downstream Quick packing allows products to be picked from one line and placed on another for finishing Automated change-overs speed throughput by eliminating format-specific change parts Handles rainbow (variety) packs allowing for greater product diversity with retailers Quick sortation of products with varying shapes and sizes to facilitate downstream operations
Objection 01 Our company was not aware that Omron
offered robotic solutions
Response 01 Omron Adept has nearly 70,000 robots installed worldwide and offers over 30 types of SCARA, articulated, parallel and mobile robots. Objection 02 I don’t have time to learn a new programming
language for robots
Response 02 Omron Adept robots can be easily programmed with Sysmac Studio using ePLC. In addition, Omron has dedicated robotic FBs that further simplify programming. Because Omron follows industry standards, a PLC programmer will be able to program the Adept line of robots, eliminating the need for a specialized robotics programmer.
In addition, Omron Adept PC-based software has intuitive wizards that will guide you through setting up basic robot functions all the way to complete packaging line solutions. Objection 03 I can buy a less expensive robot from
another manufacturer
Response 03 Omron’s value proposition goes well beyond just robotics. Omron delivers a complete solution - from sensors to control.
Omron’s complete solution includes high-performance Adept robots for applications with payloads <20 kg (44 lbs), powerful and compact controls, integrated vision, easy-to-configure ACE Sight and PackXpert software packages, knowledgeable support as well as flexible part feeding components.
The Opportunity
The company wants to create a variety pack of peppers and include a yellow, a red and a green pepper in each pack.
They want to sort by color and create a grouping of colors to be placed inline for the flow wrapper machine – without manual labor.
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The Solution
Integrate Hornet parallel robot combined with the FH-5010 vision system with 3 cameras inline to ensure the right colors are picked and placed in a straight line on a separate conveyor for wrapping.
The system is controlled by the NJ501 controller.
Confidential The Result
Throughput has increased by 5% and the company is now able to place different color peppers in the correct order for flow wrapping.
With recipe selection, they can now also easily switch between product packages running on the same line – from a variety pack to a singular color pack.
Confidential Customer Testimonial
Confidential Customer Testimonial
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Situation Questions How much capacity can your current operations handle if What affect will the cost of there is an increase in additional labor due to demand from your increased production major customers? have on your profits?
How do you handle requests for packs with a variety of different products or sizes? Problem Questions How much can you increase production How long does it take you levels before you to perform a change-over start having difficulty when your customer controlling quality? makes a special request?
How do you ensure that the right products are going into the appropriate tray compartments? Implication Questions What impact would improperly packed What is the cost of products have on delivering low your relationships quality products to with your major your customers? retailers?
What will it do to your competitive position with a retailer if you cannot easily meet production demands? Need-payoff Questions How much more product could you put How much would you on your retailers’ shelves save annually if we could if we could increase reduce the cost of labor production speed with needed for periods of reliability and accuracy? peak production?
What kind of errors do you typically see when using manual labor to perform repetitive tasks and what is the cost to correct the errors?
01 PUBLICATIONS • Automation Inside • Automation World • Canadian Manufacturing • Control Design • Design News • Design World • Food Production Daily • Manufacturing Automation 03 02 ASSOCIATIONS BROCHURE IEEE-RAS DOWNLOAD IFR Adept Food Packaging PAC Brochure PMMI
Industrial Robots Datasheet
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omron247.com - Robots
Click on images for links MyDashboard
Confidential Deliverables
Internal Solutions Training
DSI Datasheet External Sales Deck Confidential
Competitive Highlights: Robots
1. The Adept Quattro is USDA accepted 1. No competitive robotic product offering is USDA accepted
2. Omron Adept motion and control is 2. No competitive robotic product integrated into the Hornet and Cobra offering has integrated motion and robots so there is no need to purchase control external motion and drive components
3. The Omron Adept Viper 700 and 900 3. Competitive robotic offerings have robots have the most compact higher equipment density, are more controls in the industry at1/4 the size expensive to install and are more and 1/10 the weight of traditional 6- complex axis robots
Confidential Competitive Highlights: Cobra (SCARA)
• Reliable, rugged, proven • Epson is the market leader for SCARA robots • eCobra is a unique offering in the • Low cost industry • Many sizes from 175mm to • High value, cost effective (Lite) 1,000mm • Easy upgrade path to higher • Many variations: 300+ (cleanroom, performance ESD, ceiling mounts, etc.)
• No external controller, easy to deploy • ABB announced new SCARA line in December 2015 • ePLC programming – makes it ‘easy’ • Other manufacturers include: Yamaha, Denso, Staubli, IAI
Confidential Competitive Highlights: Viper (Articulated)
• Suited for complex applications with • Fanuc is the market leader for small 6- ACE software axis robots • Low cost • Suited for simple applications with ePLC • Make their own servos programming available • Leverage software from large 6- axis robots • Easy to add 6-axis robot to same controller as Cobra or Quattro • Other manufacturers include: Yaskawa, ABB, Kuka, Denso, Epson, Staubli • Save floor space and simplify installation with compact amplifier and controller package
Confidential Competitive Highlights: Quattro/Hornet (Parallel)
• Speed and product throughput are the • ABB is the market leader for parallel best in the industry robots • FlexPicker has been on the market • Small controller/amplifier footprint 10+ years • Have a packaging specific • High payload / high inertia capability software, Pickmaster (Quattro) • Other manufacturers include: Fanuc, • Suited for large work envelope Yaskawa, Kawasaki applications (Quattro)
• Superior conveyor tracking; better repeatability at all belt speeds
• PackXpert software greatly simplifies deployment
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Competitive Highlights: Control
1. The NJ SQL is the only controller that 1. Rockwell does not offer SQL built into has the embedded SQL function blocks their CPU built into the CPU and that follows SQL standards
2. Sysmac Studio integrates logic, motion, 2. Rockwell’s RSLogix 5000 has multiple vision, safety, robotics and enterprise software packages as well as add-ons inside one package and thus there is thus forcing engineers to maintain only one project file to maintain multiple project files
3. The NX-S does not need a separate 3. With Rockwell, you have to put an controller for specialty input devices intermediate controller in to add such as safety mats and edges specialty input devices which increases the cost and takes up additional space
4. The NX I/O has standard I/O and Safety 4. Rockwell has the ability handle analog I/O. Safety I/O can only handle digital input and high speed signals input Confidential Competitive Highlights: Vision
1. Omron manufactures their own vision 1. Cognex is an automation partner to systems Rockwell, providing them with both hardware and software for vision systems
2. The FQ-M positioning sensor has 2. Cognex does not offer a sensor that encoder input with redundancy check performs redundancy checks to confirm position and eliminate duplicate position information
3. The FH-3050 can process multiple 3. In multi-camera situations, Keyence can sequences at the same time. It has a only process as fast as the previous quad-core processor which allows for function – it must finish the prior faster and parallel processing in a sequence before it can start another multi-camera situation.
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