PACKAGE SORTATION INDUSTRY SOLUTION

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

Confidential

Primary Packaging

Confidential

Secondary Packaging

Confidential

Components Suppliers

Provide components to support processors / packagers

Customers like Phoenix Closures, Phoenix Packaging, Pactiv, Dolco

Packaging Category

Products or equipment supplied to the industry categories Categories like primary and

secondary

Machine Builders

Make machines for manufacturing Customers like Ulma Packaging,

Xigent Automation, Big Sky, Winpak Lane

NAICS

SFDC classification for the industry 311 Food Manufacturing

312 Beverage Manufacturing

Processors / Packagers Make products which enrich lives

Customers like Proctor & Gamble, Bimbo Bakeries, Kraft (Oscar

Meyer), Mondelez, EOS

Target Customers

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 • Beverages • CPG

• Confectionery • Cosmetics • 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.

By 2018, robotic integration in the food and beverage sector is expected to grow by 144% (PMMI)

The main driver behind the growing implementation of robots in primary packaging is the increasing demand for more varied packaging, pack counts and retail-ready packaging

PMMI states that the greatest potential for robot integration is in the dairy industry

26% of end-users worldwide have implemented parallel-style robots on their packaging lines (PMMI)

02

03

04

01

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

Implications • Increased waste due to incorrect

sorting based on color differences

• Recall liability due to the inability to pack products according to label specifications

• Decreased throughput because of the need for manual intervention for color sorting

Challenges / Issues • Vision system incorrectly identifies

products due to grayscale vision

• Hard for the system to keep up with production due to manual intervention

• Low productivity due to the lack of communication between the robot and the vision system

Omron’s Solution – Sortation and Placement

Highlights • High-speed FH vision system can

sort product by color

• Up to 8 cameras for multi-lane inspection and sorting

• Hornet parallel robots pick and place with high speed and high accuracy

Implications • Increase throughput due to speed

of communication among machinery

• Eliminate waste through 100% sortation accuracy

• Eliminate recalls with accurate and reliable pick and place functionality

The FH and Omron Adept Hornet robot are capable of high speed sorting and pick and place with color recognition and 360°rotation

NJ501 Machine Controller

FH Vision System

Hornet Parallel Robot

Implementation – Sortation and Placement

Highlights • NJ501 is a scalable machine controller that

can handle multiple functionalities

• FH vision system offers color recognition for higher speed production and can easily integrate up to 8 cameras

• Advanced diagnostics with the NA HMI

• High-speed system with Hornet parallel robots synchronized across the entire line

Featured Products

NJ501

FH series

Hornet parallel robots

NA HMI

NX I/O

NX I/O

Arrival of Products

FH Vision To Cartoner

NJ501

NA HMI

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

Our company was not aware that Omron offered robotic solutions

Objection 01

Response 01 Omron Adept has nearly 70,000 robots installed worldwide and offers over 30 types of SCARA, articulated, parallel and mobile robots.

I don’t have time to learn a new programming language for robots

Objection 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.

Response 02

I can buy a less expensive robot from another manufacturer

Objection 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.

Response 03

Confidential

The Opportunity

Confidential

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

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.

The Solution

Confidential

Confidential Confidential

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.

The Result

Confidential

Customer Testimonial

Confidential

Customer Testimonial

How much capacity can your current operations handle if there is an increase in demand from your major customers?

Situation Questions

What affect will the cost of additional labor due to increased production have on your profits?

How do you handle requests for packs with a variety of different products or sizes?

How much can you increase production levels before you start having difficulty controlling quality?

Problem Questions

How long does it take you to perform a change-over when your customer makes a special request?

How do you ensure that the right products are going into the appropriate tray compartments?

What impact would improperly packed products have on your relationships with your major retailers?

Implication Questions

What is the cost of delivering low quality products to your customers?

What will it do to your competitive position with a retailer if you cannot easily meet production demands?

How much more product could you put on your retailers’ shelves if we could increase production speed with reliability and accuracy?

Need-payoff Questions

How much would you save annually if we could reduce the cost of labor needed for periods of peak production?

What kind of errors do you typically see when using manual labor to perform repetitive tasks and what is the cost to correct the errors?

Confidential

03 ASSOCIATIONS 02

BROCHURE DOWNLOAD

Adept Food Packaging Brochure

Industrial Robots

Datasheet

01 PUBLICATIONS • Automation Inside • Automation World • Canadian Manufacturing • Control Design • Design News • Design World • Food Production Daily • Manufacturing Automation

IEEE-RAS IFR PAC

PMMI

Confidential

Internal Resources

MyDashboard

omron247.com - Robots

Click on images for links

Confidential

Deliverables

DSI Datasheet

Internal Solutions Training

External Sales Deck

Confidential

Competitive Highlights: Robots

1. The Adept Quattro is USDA accepted

2. Omron Adept motion and control is integrated into the Hornet and Cobra robots so there is no need to purchase external motion and drive components

3. The Omron Adept Viper 700 and 900 robots have the most compact controls in the industry at1/4 the size and 1/10 the weight of traditional 6-axis robots

1. No competitive robotic product offering is USDA accepted

2. No competitive robotic product offering has integrated motion and control

3. Competitive robotic offerings have higher equipment density, are more expensive to install and are more complex

Confidential

Competitive Highlights: Cobra (SCARA)

• Reliable, rugged, proven

• eCobra is a unique offering in the industry

• High value, cost effective (Lite) • Easy upgrade path to higher

performance

• No external controller, easy to deploy

• ePLC programming – makes it ‘easy’

• Epson is the market leader for SCARA robots

• Low cost • Many sizes from 175mm to

1,000mm • Many variations: 300+ (cleanroom,

ESD, ceiling mounts, etc.)

• ABB announced new SCARA line in December 2015

• Other manufacturers include: Yamaha, Denso, Staubli, IAI

Confidential

Competitive Highlights: Viper (Articulated)

• Suited for complex applications with ACE software

• Suited for simple applications with ePLC programming available

• Easy to add 6-axis robot to same controller as Cobra or Quattro

• Save floor space and simplify installation with compact amplifier and controller package

• Fanuc is the market leader for small 6-axis robots

• Low cost • Make their own servos • Leverage software from large 6-

axis robots

• Other manufacturers include: Yaskawa, ABB, Kuka, Denso, Epson, Staubli

Confidential

Competitive Highlights: Quattro/Hornet (Parallel)

• Speed and product throughput are the best in the industry

• Small controller/amplifier footprint

• High payload / high inertia capability (Quattro)

• Suited for large work envelope applications (Quattro)

• Superior conveyor tracking; better repeatability at all belt speeds

• PackXpert software greatly simplifies deployment

• ABB is the market leader for parallel robots

• FlexPicker has been on the market 10+ years

• Have a packaging specific software, Pickmaster

• Other manufacturers include: Fanuc,

Yaskawa, Kawasaki

Confidential

Competitive Highlights: Control

1. The NJ SQL is the only controller that has the embedded SQL function blocks built into the CPU and that follows SQL standards

2. Sysmac Studio integrates logic, motion, vision, safety, robotics and enterprise inside one package and thus there is only one project file to maintain

3. The NX-S does not need a separate controller for specialty input devices such as safety mats and edges

4. The NX I/O has standard I/O and Safety I/O. Safety I/O can only handle digital input

1. Rockwell does not offer SQL built into their CPU

2. Rockwell’s RSLogix 5000 has multiple software packages as well as add-ons thus forcing engineers to maintain multiple project files

3. With Rockwell, you have to put an intermediate controller in to add specialty input devices which increases the cost and takes up additional space

4. Rockwell has the ability handle analog input and high speed signals

Confidential

Competitive Highlights: Vision

1. Omron manufactures their own vision systems

2. The FQ-M positioning sensor has encoder input with redundancy check to confirm position and eliminate duplicate position information

3. The FH-3050 can process multiple sequences at the same time. It has a quad-core processor which allows for faster and parallel processing in a multi-camera situation.

1. Cognex is an automation partner to Rockwell, providing them with both hardware and software for vision systems

2. Cognex does not offer a sensor that performs redundancy checks

3. In multi-camera situations, Keyence can only process as fast as the previous function – it must finish the prior sequence before it can start another

Restricted for use by Omron Account Managers Do not copy or distribute; for internal use only