By Thomas R. Cutler
Automation equipment is capable of handling loads of raw material, including work in progress such as beer, soft drinks, cereals, candy and
snack foods, in addition to finished goods. Reduced operational complexity and costs, improved workplace health and safety, and improved product tracking are some examples of the benefits to using automation equipment.
But it comes down to more than just putting the automation in place – unique expertise and skills are a crucial component of the successful planning and implementation of an automation program. And finding this expertise can pose a significant challenge.
Based in Sellersville, Pennsylvania, Hesham Mahmoud, President of Strategic PM Solutions, Inc. (www.strategicpms.com), suggests that, “More than 80% of food firms experience defective or inferior automation implementation, because process solutions and an objective material handling operations strategy were not carefully analyzed and developed before selecting an AGV vendor.”
He also noted, “In the next ninety days, more than a thousand food, beverage, and consumer product goods companies 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.”
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.
Automation for the Food Industry
Increasing profits with AGV automation is best achieved by improving efficiencies in supply-chain management:
- 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
Mahmoud states, “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 include examining on-going changes in the needs and requirements of customers, and improving product quality and safety. We have seen huge value in assisting fast-changing operational environments and product movement from the material handling viewpoint.”
These solutions go beyond AGV’s – software for scheduling, routing, monitoring and visualization of the complete end-of-line process must also be considered. The food sectors’ special requirements for hygiene, safety, and data tracking are leading requirements of effective system designs.
Elettric 80 (http://us.elettric80.com), based in Skokie, IL is one of the leading AGV suppliers providing end-of-line automation solutions to the food sector.
The firm takes the position that technology alone is not the sufficient – it’s also about listening to their customers. “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 solutions to industry that set us apart from other suppliers,” noted Johan Castegren, Managing Director, Elettric 80 SpA.
Some components of a successful program include:
- 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
Risk identification leads the way to project success
A risk-based approach to project management deals with the experience of project managers and the project team, and how well the project is run, controlled, and finalized.
“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 will deliver on the customer’s goals and objectives, and whether he/she can meet the specifications,” asserts Mahmoud.
According to A Guide to the Project Management of Knowledge, PMBOK, 6 processes are used when risk is applied to project management – these help to minimize negative events:
- Plan risk management
- Identify risks
- Perform qualitative risk analysis
- Perform quantitative risk analysis
- Plan risk responses
- Monitor and control risks
Multi-Discipline Expertise Is the Key
Food and CPG firms that have purchased an automation technology solution often experience delays, resistance, and even implementation stoppage because the process and products were poorly conceived.
Few automation experts have the multi-disciplinary experience needed to drive a successful AGV implementation. The need to govern a variety of disciplines including engineering fields (mechanical, software, and electrical), plus manufacturing, purchasing, customer support and aftermarket – is why few independent consultants possess the technical skills needed, and why it is important to choose wisely.
Author Profile:
Thomas R. Cutler is the President & CEO of Fort Lauderdale, Florida-based, TRCutler, 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.
