Suppliers of end-of-line automation and material handling in the food sector have a distinct scope of technology to consider, including various types of palletizing robots, stretch wrapping equipment, labeling systems, pallet control systems, and laser-guided automatic vehicles.

These solutions go beyond AGV’s and must contain software for scheduling, routing, monitoring and visualization of the complete end-of-line process. The food sectors special requirements for hygiene, safety, and data tracking are leading component required of effective system designs.

Automation equipment is capable of handling loads of raw material; work in progress such as beer, soft drinks, cereals, candy, snack foods; and finished goods. Based in Sellersville, Pennsylvania, Hesham Mahmoud, President of Strategic PM Solutions, Inc. (www.strategicpms.com), suggests that, “More than eighty percent (80%) of food firms experience defective or inferior automation implementations because an objective material handling operations strategy and process solutions within the food facility has not been carefully analyze and developed before selecting an AGV vendor.”

In-Process Automation Implementations

Food and CPG firms that have already purchased an automation technology solution, often experience delays, resistance, and even implementation stoppage because the process and products were poorly conceived.  An independent liaison between the internal client staff and the AGV vendor, is frequently needed. An objective mediator, with knowledge and experience within the sector, saves months, even years, in the implementation and execution of best practices on the plant floor, distribution center, or warehouse.

Typical automation application may include a phase or multi-phases of the following product movements:

• Unloading raw material from trailers to receiving
• Raw material from receiving to storage
• Raw material from storage to work in progress (WIP)
• Finished goods from work in progress (WIP) to storage
• Finished goods transportation from storage to the shipping area
• Loading of finished goods from shipping area to the trailers

The benefits of utilizing automation equipment and improved processes are:

• Reduce operating costs
• Optimize use of operations and facility space
• Improve product quality
• Improve workplace health and safety
• Reduce labor costs
• Improve quality of work for employees
• Increase production throughput
• Reduce products waste
• Improve products tracking

Finding objective automation expertise is a significant challenge.   By utilizing automated guided vehicles (AGVs), robots, conveyors and automating equipment companies minimize the potential of product damages.  The industry sectors most impacted by the use of automating equipment than food, beverage and CPG (consumer product goods) companies. 

Mahmoud also noted that, “In the next ninety days, more than a thousand food, beverage, and consumer product goods companies in will implement an automation solution in a manufacturing plant, distribution center, or warehouse. Sadly, four out of five of these automation projects will be troubled, resulting in a waste in time, money, resources. Only objective and experienced project management expertise can help avoid these disastrous and misguided implementations. There is often a lack of internal expertise or resource in project management and industrial automation.”  AGV solutions providers, no matter how well intended, have an agenda to sell their products and solutions.

Increasing profits with AGV automation is best achieved by reducing costs related to supply-chain management.  Exploring methods of optimizing transportation of raw materials, work in progress, finished goods and flow of return goods drives bottom-line results. Production issues, particularly workflow, can improve operational efficiency and employee productivity. 

Integration of equipment and processes along with operational complexity and dealing with best practices also generate economic impacts for cost-justification of the AGV automation expense.

Elettric 80, based in Skokie, IL,  is one of the leading AGV suppliers providing end-of-line automation solutions for the food sector.  The firm takes the position that  technology helps companies cut cost and move product to and from the production area and out of the warehouse in a fast and effective manner. ”Our goal is to work with customers to establish innovation and challenge the boundaries at the end-of-the-line. We are always looking to improve our proposition and offer the industry solutions which set us apart from other suppliers, ” noted Johan Castegren, Managing Director, Elettric 80 SpA.

• A rapid installation and start-up

• An immediate improvement in overall performance

• A safer work environment

• Lower maintenance costs

• Greater flexibility within the facility

• A quick return on investment

• The ability to perform real-time checks on load data

• An optimization of floor space

• Easy to implement expansion plans

Mahmoud also suggests, “Maintaining up-to-date production processes, technology, and project management training are vital elements to consider in Food and CPG companies.  Other areas of cost containment can be found when examining on-going changes, needs and requirements customers, and improving product quality and safety.  We have seen huge value in assisting fast-changing operations environments and product movement from the material handling viewpoint.”

Extensive expertise in the material handling automation and strategic project management allows distribution centers, warehouse operations, and manufacturing plants to lower project costs and assist with production and processes challenges. These aspects must assist with the material handling transportation and automation solutions to improve and drive production, performance, and profitability.

Risk identification leads the way to project success

When risk is applied to project management, six processes are used in project risk management, according to A Guide to the Project Management of Knowledge, PMBOK. These processes minimize the negative events.

Project management risk processes

• Plan risk management
• Identify risks
• Perform qualitative risk analysis
• Perform quantitative risk analysis
• Plan risk responses
• Monitor and control risks

“Risk generally falls into three categories: technical elements, project management, or business and external forces. Technological risks are the most crucial because they are the ones that measure project performance. Project managers have to ask if the project can deliver the customer’s goals, objectives, and if he/she can meet the specifications, ” asserts Mahmoud.

Project-management risk deals with the amount of experience of the project managers, project team and how well the project is run, controlled, and finalized.

Multi-Discipline Expertise Is the Key

Few automation experts have the multi-disciplinary experience needed to drive a successful AGV implementation.  Governing a variety of disciplines including all engineering fields, such as mechanical, software, and electrical, plus manufacturing, purchasing, customer support and aftermarket is why few independent consults possess the technical skills needed in automation,  management and operations.

Author Profile:

 Thomas R. Cutler is the President & CEO of Fort Lauderdale, Florida-based, TR Cutler, Inc, (www.trcutlerinc.com). Cutler is the founder of the Manufacturing Media Consortium of nearly four thousand journalists and editors writing about trends in manufacturing.  Cutler is a member of the Society of Professional Journalists, Online News Association, American Society of Business Publication Editors, Committee of Concerned Journalists, as well as author of more than 500 feature articles annually regarding the manufacturing sector. Cutler can be contacted at trcutler@trcutlerinc.com or 888-902-0300.