Embracing change: Explaining the process of flexible manufacturing

The rapidly changing consumer goods market is undergoing a transformative shift due to factors such as consumer empowerment, demand for customization, health-conscious preferences, veganism, ethical issues and sustainability. We expect to see more change in the next decade than in the past 50 years. This requires the adaptation of production and supply chains to emerging trends. The future of factories for fast-moving consumer goods is likely to involve smaller, smarter facilities with autonomous movement of goods and interconnected systems.

Machinery, whether operating independently or interconnected, must be more flexible than ever to ensure timely delivery of the right materials and packaging. Production must be more flexible, so that more items with high variation and low volumes are produced without recalls. The question is: How can we achieve this with minimal cost and quick ROI?

Workflow at three levels

To achieve the optimal solution with maximum flexibility, it is important to consider several factors. A practical approach, such as OMRON's, focuses on optimizing processes to minimize interruptions. This includes dividing the workflow into three functional levels:

Level 1 - Before the machine - Intralogistics

Before reaching the production line and machine level, the focus should be on ensuring flexibility in the production line, thanks to just-in-time delivery of consumables, optimization of transportation of goods, boxes and pallets, and management of semi-finished goods, waste and unused consumables. The goal is to avoid storing consumables and semi-finished products on the shop floor.

Level 2 - At the machine - machine supply.

At the machine level, the focus is on automating material verification and feeding processes, replacing manual feeding operations with automated feeding, performing quality assurance on packaging materials and ensuring package integrity after packaging.

Level 3 - In the machine - machine setting

Inside the machine itself, all functions such as machine control, motion, robotics, sensing, vision and safety are automatically tuned. This ensures that tasks such as filling, capping, loading trays, closing, sealing and labeling are performed as quickly as possible, improving overall efficiency.

For the machine: Enabling flexibility in the production line

Designing, building and optimizing a process and packaging line requires expertise and experience to ensure that maximum benefits are derived from an investment. Improving line performance by optimizing the flow of goods and consumables on the plant floor and adjacent storage areas is essential.

At the machine: automation of material verification and feeding processes

Controlling optimal replenishment is a key element to improve overall equipment effectiveness (OEE), eliminate waiting time and minimize intermediate inventory on the plant floor. The focus here is on package and container loading, as well as the efficient output of finished goods. The goal is to ensure timely and direct material supply without any manual intervention, eliminating line disruption and reducing the risk of errors.

At the machine: Streamlining machine functions for improved efficiency

What happens inside the machine? Efficient processing of products is critical for maintaining throughput and preparing them for downstream processes. Delta-style robots, along with smart conveyor tracking capabilities, are ideal for fast, accurate, repeatable and efficient processing, such as precise pick-and-place operations. Software can optimize flow rates and recipe processing to ensure seamless integration and operation. With one controller controlling motion, vision, safety and robotics, OMRON offers a comprehensive solution for streamlined machine functionality.

The benefits

Automation of manufacturing processes for flexible production offers numerous benefits, including:

- Capacities for faster product changeovers enable rapid adjustments and changes to production lines, reducing changeover time and optimizing performance.

- Enhanced tracking and analytics provide valuable insights for continuous improvement and optimization of workflows.

- Increased employee satisfaction thanks to focus on value-added tasks and more on strategic and creative work.

By leveraging the benefits of automated flexibility, companies can achieve greater operational efficiency, worker safety, cost savings, product innovation and improved competitiveness.