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Package Sortation and Placement 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 Confidential 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. Confidential 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. Confidential 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 Confidential 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
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