Pie, Robot

The use of robotics has been widespread in many sectors where fast and accurate assembly has been a top priority.

However, up until recently UK food manufacturers have been slow to adopt robotics, perhaps partly due to fear of the unknown, partly the perceived long payback period and partly lack of application understanding.

But these are changing times. According to the British Automation and Robot Association (BARA), UK robot sales reported at the half-year point in 2013 have accelerated, almost matching the level for the entire year of 2011.

Even though the UK is reluctant in its adoption of robotics compared to its EU counterparts, figures show that 1,286 robots have been sold in the first two quarters of this year, compared with a total of 2,000 robots in the record year of 2012.

Most importantly, sales of non-automotive sector robotics are double what they were in 2009 and if the adoption of robots in the food industry continues as it has begun, this year could see as much as a 70% increase in food sector sales compared to 2000.

Recent sales figures are a testament that the programme has gone some way to addressing concerns

Chris Sumner

So, why the change? Looking to bust the myths and common misconceptions surrounding automation, the recent £600,000 government-funded Automating Manufacturing Programme, managed by BARA, gave UK manufacturers impartial advice on the implementation of automation solutions.

The programme was in response to recommendations made in an industry study in 2010, Application of Automation in UK Manufacturing, which polled a broad spectrum of manufacturers of engineered products and food in Spain, Germany, Sweden and the UK.

The study not only aimed to find out why the UK lags behind the rest of the world in the adoption of automation, but looked to address the issues with an action plan of initiatives to stimulate growth.

Results from the study, which was commissioned by members of the Engineering and Machinery Alliance (EAMA) with support from the Department for Business, Innovation and Skills (BIS), concluded that the main reasons for UK manufacturers’ reluctance to invest in modern manufacturing technologies were due to a lack of knowledge, skills and confidence.

Over the course of the 18 month Automating Manufacturing Programme, which began in September 2011, 366 UK manufactures took a risk-free plunge into the automation arena, around 40% of which were food manufacturers.

The programme, which initially offered a free audit of the manufacturer’s operation and identified potential opportunities to apply automation, was followed by implementation support.

The recent industry robot sales figures are a testament that the programme has gone some way to addressing concerns that prevented manufacturers from automation uptake.

Robot cost and the perception that paybacks are lengthy has been addressed by Fanuc’s robot redevelopment programme, which has resulted in a 20% reduction in parts on the latest palletising and pick and place models.

Fewer moving parts not only results in a more robust system, but has led to a fall in prices, enabling manufacturers to receive a more desirable payback, often within 12 months.

Perceptions relating to robot occupation have also changed now that manufacturers have a better understanding of the ease with which a robot can be redeployed into a new role.

This addresses a common problem created by retailers placing short-term contracts and manufacturers not knowing how their automation needs may change over the course of a year.

As well as improved perception, increasing demand for robotics in the food sector has also been driven by legislation.

Over the course of the last 10 years, food manufacturers have faced greater pressure to adhere to increasingly stringent levels of compliance.

Whether responding to individual Retailer Codes of Practice (COP) or the latest requirements set out by the British Retail Consortium, manufacturers must demonstrate tight product control and complete line integrity.

Manufacturers looking to improve hygiene, by removing the uncertainty the human element brings to the equation, have been driving the need for food-grade equipment.

Not only does the integration of robots enhance a food manufacturer’s competitive edge through increased productivity, reduced waste and greater profitability, for some food companies with arduous, labour-intensive manufacturing processes, it’s the robot’s ability to reduce injuries to their workforce which matters most. Unlike manual staff a robot doesn’t need holiday nor does it lose concentration.

However, embracing robotics doesn’t mean food factory staff will lose their jobs: projections suggest that two million jobs will be created in the next eight years because of the robotics industry, as indicated by a recent study by the International Federation of Robotics.

Further to this, 60,000-80,000 new activity jobs will be created in the food industry alone between 2012-2016.

Fanuc helps retrain staff to use robotics at its new 3,000m² interactive facility in Coventry. Fanuc’s Japanese development team are working hard to bust robot myths and with their adoption, help food manufacturers create a new competitive edge.