Is automation a recipe for success?

Consistent Quality Control and Preventing Product Recalls

If you are accustomed to purchasing a product, you expect it to be the same each time, you expect to recognise the flavours and for the texture to be identical. You expect it to be consistent. As human beings, we naturally fall victim to human error no matter how great or small. The simple fact is that a single error in food production could be detrimental. With various touch points throughout the process, without technology it is incredibly difficult to monitor quality and this job would fall to an employee to assess. Perhaps sufficient in a small production line, this process would be far too time consuming in a dynamic, fast paced environment, hence the implementation of automation. Programmed to perform the instructed action repeatedly, production machines improve line efficiency, speed, food safety and of course, minimise the risk of human error. As a result your brand image is safeguarded as happy customers have no need to return goods. 

Traceability and Visibility Using Data

Nowadays, consumers have a need to know how their produce is made and what goes on behind the scenes. In reality, recalls are not completely out of the picture and there is always a chance of them rearing their heads, however having an automated process in place means data on the origin of the fault will be available. Identifying the root of the problem lends itself to damage limitation and the preservation of your company reputation. 

The uses of this data goes beyond just production line traceability and into market analysis. For instance if your production data shows an increase in manufacturing a certain food, you can determine an increasing demand for said product, pinpointing trends and analysing consumer behaviour. Once you have this data and knowledge, it can assist you with future product development and sales forecasts. There is a reason why data is so very valued!

Increased Efficiency and Production Output

Linked closely with data is efficiency and output. Provided you have the correct automation machinery in place and each one is effectively communicating, they can run around the clock, meaning more produce is produced and time is efficiently managed. The real time data received can also indicate when maintenance will be required, allowing for planned preventative  maintenance and downtime. For example, if a machine is showing to be running slower than usual, this flags as a warning on the HMI to be aware of the maintenance needed.

Flexibility and Adaptability

Changes in consumer trends mean the production process follows suit. With a solely human workforce, these changes may mean months of training to operate new machines, however with an automated process, the solution can be as simple as reprogramming a PLC with fresh instructions.

Reduce Waste

According to the Food and Agriculture Organization (FAO), 1.3 billion tonnes of food is wasted globally per year. Waste management throughout the production process has therefore become a key focus. By monitoring the data produced by automated machines and only creating the products needed saturating the market and supermarket shelves with produce which is destined to surpass its sell by date before being consumed. The enhanced quality control also assists with the fight against food wastage. If a food is correctly packaged  and of good quality, shelf life is increased. For instance, if you had a horrifying discovery of mold on bread due to poor packing methods, it would meet its harsh fate in the bin, however having gone through an automated packing process, the life of the bread will be preserved for longer, hopefully resulting in a much more positive outlook for your loaf.