Festo Flexibilityebook r4 Opt 0

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity
How Electric Automation Reduces Changeover for Increased Efficiency
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Table of Contents
03. Flexible Management of Variants
05. Modular Handling System
07. Fast Filling
09. Automatic Tool Changer
11. Vacuum Tooling Reduces Changeover Time
13. Kelloggs Quest for Manufacturing Innovation
15. Improving Sustainability with Automation and Controls
16. Will 2015 Be The Year Of The Robot?
18. Mondelez Embraces the Future with Integrated Control Solution
21. Flexible Manufacturing at Chrysler
23. Pneumatic Valve Terminal
25. Automotive: Handling with Care
29. Lab Innovation Based on Toy and Material Handling
31. Additional References
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Flexible management of variants

matics and proportional technology from Festo.
Maximum flexibility is the name of the game for BDG when
building customer-specific systems. Their test and production
systems consist of individual modules, so that end users can easily respond to market changes by re-configuring the systems and
increasing capacity. Only in this way can we be true to our motto
The future belongs to the flexible, says Lars Brenner, Head of
Organization and Administration at BDG.
The best example of this is the new BDG assembly and test machine for the production of pipe plugs for valves. The machine is so
flexible that it can be used to produce many variants of pipe plugs.
On a single machine, the upper and lower parts of the pipe
plugs are brought together, pressed, laser welded and finally
tested to see that the welds are free of leaks. The process steps
take place so quickly that the finished pipe plugs leave the
machine within a short cycle time.
Separate assembly lines and job changeovers on-the-fly are
somewhat unusual for a 50-person company. But not for the
special machine builder BDG in southern Germany, who combines modern management methods with efficient servopneu-
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Job changeovers on-the-fly

For our customers, this machine represents a huge productivity gain, says Brenner. Up to now, they may have used several
semi-automated machines for different variants, which are not
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capable of handling all the diameters and lengths involved. In

the new machine, two spiral drum conveyors now allow a job
changeover on-the-fly.
Another reason for the flexibility of the machine is the
pneumatic automation technology from Festo with which it is
equipped. Already in the first station, the position controller
CMAX drives two axes DGCI. These servopneumatic axes travel
to different positions, depending on the pipe plug type and the
required cycle time. Grippers HGPT in conjunction with a sensor
SOEC place the lower pipe plug parts on workpiece carriers, and a
conveyor system transports them to two gantries.
Sophisticated servopneumatics
The gantries, which are supplied ready for installation in the
system and consist of spindle axes EGC and standards-based
cylinders DNCE, place the upper parts on the lower pipe plug
parts. The following station then presses the two parts together
and laser-welds them.
The test station is full of evidence of Festos servopneumatic
know-how. Groups of four times four axes DGCI with intermediate position modules and Soft- Stop CMPX for two end positions
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Modular Handling System

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and intermediate positions are the perfect answer to the users

needs. Thanks to servopneumatics in the form of the proportional valve VPWP, pneumatic axes are able to provide similar
properties to electric axes but at a much lower cost.
Ready-to-install pneumatics
Complete mounting plates equipped with 18 individual valves
CPE and service units from the MS6 series provider the safety
functions required for the proportional valve VPWP.
The ready-to-install handling gantries and the mounting
plates have helped us to focus on our core competence, testing
combined with automation. We were able to complete the machine in the allotted time of nine months, reports Brenner. n
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Modular Handling System

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Modular Handling Platform

Integrated laboratory automation
system in just one desktop unit:
motion, PLC and vision
Festo has developed a scalable compact
handling platform with predefined
modules, which significantly reduces the
engineering costs of small-component
handling units.
World-wide Festo standards for compact systems this is Festos objective as
a means of gaining further market share
in laboratory automation.
We are accordingly working on a scalable modular handling platform with
predefined and standardized modules.
The creation of a selection table for various
sub-systems makes it possible for our
partners and customers to configure tailormade handling systems with a desktop
format at minimal engineering cost.
This prevents over-engineering and
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allows the development cost of smallcomponent handling systems to be

significantly reduced.
This future-oriented concept for flexibility to order is based on a standard system
with three development levels, matched
in each case to customers requirements.
Overview of the three

development levels of the
handling platform
Level 1: basic handling system on a

mounting plate with modules which
can be combined flexibly and are
perfectly matched together, including
basic software functions
Level 2: handling cell, derived from
the basic handling system, with a
housing, control cabinet and additional software functionality
Level 3: handling cell with customer-
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specific adaptation of the hardware

and software
Laboratory automation made easy

This modular system, which allows the
flexible combination of modules, offers our
customers and partners predefined spaces
in which they can configure processes
freely for their specific applications. The
cells will be available in scalable sizes.
Depending on the application concerned,
the control cabinets can be mounted at the
side, at the rear or separately.
The workpiece carriers can be transported both within the handling cell
and also outside with a choice of
either manual or automated workpiece
handling. It will be easy to integrate the
handling platform into existing processes
and to link together several units using
defined interfaces.
Solution installed on a mounting plate or
integrated into a handling cell with clear interior and

exterior system limits with regard to mechanical and
electrical components and software.
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Fast Filling

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The basic handling system consists of:
Kinematic system
Flexible configuration of the handling solution for small workplaces.
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Mini slides EGSI, EGSK or the linear gantry

EXCM-10/30 can be combined flexibly with
one another or installed individually in
order to transport sample carriers or tools
within the working area.
Motor and controller package
A combination of servo motors and the new
high-performance controller CECC-X for
movements and program sequences allow
dynamic and precise positioning. Overview
of controller performance:
2x 866 MHz, 512 MB DDDR-1066 RAM,
22 digital inputs, 16 digital outputs,
4 analogue inputs and 4 direct motor
controller connections; 2x CAN, 2x gigabit
EtherNet (TCP/IP and EtherCAT), 2x USB 3.0,
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IO-Link, RS232/485
Basic software functions
These allow easy commissioning of the integrated hardware components using simple
travel commands, teach-in functions or error
handling on the basis of CodeSys V3.
Today a concept, in the future a worldwide standard

This modular handling platform emphasizes
Festos product and process knowledge which
allows us again and again to set new standards
for our customers with regard to efficiency,
flexibility and productivity.
We seek out partners to work with us on
future development, allowing us to create the
standard solutions of tomorrow. n
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Fast Filling
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Fast filling
In the fast-moving world of specialty salads and convenience meals,
the machines built by Robot Food Tech ensure that the results taste
good. These machines fill, seal and pack culinary specialties into
various containers. Festo automation in the form of servopneumatic
components, sensors and process drives, sets the pace.
different sizes. It is due in no small measure to these short changeover times that this machine builder is regarded as among the
worlds leaders in specialty food processing.
With pride, the company promotes the slogan Liedership in
Packaging, reflecting the fact that Robot Food Tech has for years
sold and serviced traditional filling and packaging systems worldwide under the Lieder brand name.
The RCF robotic filling machine is distinguished by its short setup times.
Serving with high positioning accuracy
What requires hours with other filling and packaging lines during format changes, takes us just a few minutes, declares Harald
Grne, Managing Director of Robot Food Tech. Grne is speaking of
the set-up times to change the filling modules over to work with
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The best example of the high speed delivered by Robot Food

Tech from its factory in northern Germany is the RCF robotic filling
machine. This achieves output rates of up to 800 fillings per minute.
For the RCF filling machine, it is an easy task to fill products such as
salads, jams, butter, or sauerkraut to precise weight specifications.
The containers are hermetically sealed after filling. This is the only
way the quoted Best before date can be achieved. A gasification
station feeds nitrogen through ducts to the filled containers. This
reduces the residual oxygen to a safe 0.1% of the original volume.
The nitrogen supply is regulated by a DLP, a pneumatic linear drive
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Automatic Tool Changer
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for process automation applications, while pressure sensors control the correct pressure for the nitrogen. The welding of sealing
film is the last step in the filling and packaging process.
Servopneumatic portioning
Servopneumatics is responsible for the precision of the filling
operation. A Festo controller CMAX is used here for the fine
regulation of the position and force of
the pneumatic drives. Thanks to this technology, our systems
are able to benefit from the state of the art in automation technology, says the young entrepreneur.
Servopneumatic drives are better than electric drives for this
application. Electric drives have great difficulty in meeting the
criteria for the protection class IP65 required in the food industry.
Worldwide presence
In addition to Festos ability to supply servopneumatic components, there is another reason why Robot Food Tech has chosen to
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work with this supplier. We export 80% of the machines we sell.

We therefore need automation technology suppliers whose components and systems are available in every corner of the world in
just the same way as our filling machines for convenience meals
and specialty salads are, says industry ex- pert Grne. n
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Automatic Tool Changer

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Automatic tool changer

The first machine of its kind changes robot tools
for packaging machines fully automatically
at Gerhard Schubert GmbH. With Festos valve
range VUVG as one of their central components the TLM packaging machines, made
in Crailsheim, southern Germany, achieve a
hitherto unattained level of efficiency.
Small, large, round, square, aluminum, plastics, cardboard and composites food packaging has never been as diverse as it is today. This
is not just because of the increase in hygiene
requirements but also because packaging is
used as the brand identity for products and companies. This development also has an impact on
the manufacturers of high quality packaging
machines. They must be ever faster, increasingly
flexible, more and more compact. And so the
hand of Schuberts TLM P3 robot has become
more and more complex over the years.
Apart from the core task, holding the tool,
the robot hand must also fulfill many addition-
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al requirements. These include, for example,

transferring energy and data
for the sensors and valves on the tool. It also
transfers the relevant codes to the tool. But the
more complex robots and tools become, the
more difficult the tool change turns out to be.
Gerhard Schubert GmbH realized it was time
for a fully automatic format conversion process
using an automatic tool changer.
a toothed pinion. The energy and data are transferred inductively. The transmodule delivers
the tools to their destination with a positioning
accuracy of up to 0.1mm. Acceleration of up
to 0.5 g ensures it gets there fast. The tool is
removed and transported in about 40 seconds.
Immediately after that the packaging machine
starts the new format.
Transport in seconds
Progress with a tiny

footprint
The principle of the automatic changing

process is simple. With the new tool changer
the TLM P3 robot takes the suitable format tool
for the relevant product from a tool cupboard
specifically designed to basic europallet dimensions and transfers it to a TLM transmodule.
As the first transrobot in the world the transmodule can move freely on the track system of
a packaging machine. It is driven by a servo motor that engages into a gear rack by means of
The central interface

of the automatic tool
changer is the valve range
VUVG. It transfers energy
and control pulses quickly
and reliably. And its design is extremely compact.
Its tiny footprint fits in
well with the compact
design of the automatic
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tool changer and means it can be fitted directly

on the cylinder. A flow of up to twice that of
traditional valves ensures high energy density
with a pressure power of up to 10 bar.
The high level of modularity of the valve range
was also advantageous for the development of
Schuberts automatic tool changer. By moving
the packing glands, the base plate can be easily
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Interview: Trends in Automation

Reiner Weldmann,
Sales Director at Gerhard Schubert GambH
As a manufacturer of packaging machines, how do you deal with the
trend towards always having to supply them more cheaply?
Reiner Weidmann: With highly flexible packaging machines that
customers can also use for other products. With easy expansion and
conversion options. That is one of the fundamental differences between
low-cost and high-end machines. Its not only the low purchase price of
a packaging machine that is critical for a companys success. Its also its
availability, quality and service, i.e., what is called the life cycle cost, that
need to be considered.
Do components also play a critical role?
Weidmann: Definitely. In principle, we can use any product, any
valve on the market. However, if you want to achieve sustainability with
appropriate life cycle costs, you must use high quality components. Factors such as the technical quality of the product, the market leadership
of the manufacturer and the reliability of the supplier also carry weight.
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How important is the size of a packaging machine today and how can
the dimensions be reduced still further?
Weidmann: The size of a packaging machine is very important.
Space is money. The more space a machine takes up, the more expensive
it is for the customer. Dimensions can be reduced by using standardized
components that are designed to be small. Add to this the important
role played by state-of-the-art technologies. Machines that were once
rigidly synchronized using chains are now being replaced with intelligent machines that move products flexibly.
In the food industry, how long do people expect packaging machines to last?
Weidmann: Our machines can be operated for 10, 15 and 20 years.
The problem is, however, that companies want to spread the risk over
two, perhaps three or, at the most, four years.
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converted and adapted to the required functions. On the front

individual valves can be replaced by dummy plates by undoing
two screws and doing them up again. This is how Schubert makes
up to 30 variations based on three components.
Low consumption, high availability

In this simple but intelligent way, the world market leader in
top loading packaging machines is constantly increasing the
flexibility of its equipment. Short tool changeover times, low
energy consumption and continuous availability of the high-end
machines gives this company with its 40-year old success story a
decisive competitive edge on the world market for food packaging machines. n
Gerhard Schubert GmbH

www.gerhard-schubert.de
Area of activity: Flexible packaging solutions,
TLM packaging machines, systems and robots
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By Pat Reynolds, VP Editor, Packaging World
AMF Bakery Systems, the worlds leading manufacturer of high
speed bakery equipment, makes robotic systems that commercial bakeries use to transfer freshly baked buns and other
products from primary packaging lines to bread trays bound for
distribution centers. The company saw a need in the market for
a flexible, lightweight, end-of-arm robotic tooling with a dense
population of vacuum cups. AMF envisioned that each cup could
be independently turned on and off, allowing the same tooling
to pick and pack different patterns of products.
Existing solutions required the tooling to be changed out for
each different loading pattern or product size. This extended
changeover times, and in some cases it required maintenance engineers to perform the changeovers instead of the line operators.
The existing methods also required the sub-elements of the pick
patterns to be isolated as the tooling would pick up whichever
product was underneath it in the pick area. In other words, if the
pick pattern were two packages of buns, for example, only two
packages could be sent down the conveyor to the robot at a time.
On some production lines, buns had to be packed into trays by
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hand because the tooling in use could not do the required pick
and place. This situation, of course, required substantial labor.
Festo helped AMF Bakery Systems design a programmable
dense-cup-population tooling that solved these problems on
the packaging line. The new system quickly became part of AMF
Bakery Systems standard offering and remains so today. The tool
design and the design for supplying vacuum, a
path for both electrical and control cables to the
tool, proved unique enough to have patented.
Weight limitations of the robot were a primary concern, as was size, said Roy A. Miller,
Senior Sales Engineer, Festo. So Festo began
the design process by identifying a small, lightweight, single-acting pneumatic cylinder with
return springthe Festo EFKthat would be
used to turn on and off each vacuum cup.
Dave Thomas, Senior Applications Engineer
at Festo, adds this. To control the cylinders,
Festo included a CPV10 valve manifold. This
was also a lightweight and small solution
engineered for tight spaces. AMFs engineers
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put eight different manifolds on the end-of-arm tool, bringing

the manifolds as close as possible to the EFK cylinders. Each
CPV10 manifold had 16 valves. This was sufficient to control all
128 vacuum cups.
Only one airline was needed to bring air to the end-of-arm
tooling. At the end-of-arm tool the air was split into eight lines,
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Kelloggs Quest for Manufacturing

Innovation

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one for each manifold. Also on the end-of-arm

tool was an Ethernet/IP gateway. This limited the
number of communication cables that had to be
run down the robot arm.
The CPV10 manifold integrated to the Festo
CPX control platform. With this arrangement, all
128 vacuum cups can be controlled individually.
AMF chose a pneumatic solution over others as it
met functionality, weight, and control needs. The
physical size worked well with the size of the tooling and the available area on it for mounting the
valve controls. The simplicity of the valve control
also met AMF Bakery Systems expectations for
keeping the complexity level low to ease mainte-
Sponsored by
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nance interactions with the valve controls.

AMF Baking Systems realized its vision for
a better packaging line, said John J. Keane III,
Executive Product Manager Packaging and Automation, AMF Bakery Systems. The new system
has eliminated changeover time and increased
production rates.
Customers around the world rely on AMFs
expertise in the high speed bread, bun, and soft
roll baking market. The programmable densecup-population tooling is an example of how the
company works diligently to produce solutions
that represent industry leading quality, innovation, and value. n
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Kelloggs Quest for Manufacturing

Innovation

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Kelloggs Quest for Manufacturing Innovation

By Stephanie Neil, Senior Editor
Implementing a steady stream of manufacturing innovation can feel like an impossible task,
especially when youre a company like Kellogg,
the maker of such iconic brands as Special K, Rice
Krispies, Pop Tarts and Pringles, which has 33,000
employees in over 60 plants across 20 countries.
Each of the companys brands has its own
operating model using different technology
and go-to-market strategies, says Bob Reed,
Kelloggs vice president of global engineering.
And, that, he says translates into a complex
supply chain that requires high performance
and efficiency to deliver on Kelloggs vision to
enrich and delight the world through foods
and brands that matter.
Thats an engineering challenge, he says. For
example, a high performance manufacturing
line developed in the U.S. wont perform the
same way in an emerging market, as there will
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be different metrics and scale related to brand

equity in different places. With that in mind,
the company set out to create a repeatable
process that can be used in any plant and that
ensures continuous improvement in operations
while engaging cross-functional partners.
Now, Kellogg is in the midst of developing
a methodology the company calls Integrated
Project Delivery (IPD, a system designed to
achieve continuous process improvement in
both developed and emerging markets.
IPD is divided into four areas: People, alignment, technology, and process.
First, all stakeholders need to understand
what is to be delivered for the business, and
specifically, the definition of the project deliverables. You want to avoid that shocking moment
when the project is finished and Im proud of
what I did, but someone else didnt think thats
what I was going to do, Reed says. Its important to deliver the project success criteria.
Its also always important to keep money in

mind. You wont achieve the business objective if you dont have a cost-effective line, he
says, so scope management is essential. To that
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end, instead of adjusting the previous years

spending, start each departments budget
from scratch a method known as zero-based
budgeting which forces cost justification. This
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allows us to take on a lot of new projects that

we might not have taken forward in the past
due to cost, Reed says.
Part of the cost comes in the form of technology and defining technology requirements for
each project--- because you can have the best
technology in the world, but if it doesnt fit the
application, it doesnt matter.
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Knowledge management also becomes critical

to the advancement of technology. Every line
we build has to be better than the last one, says
Reed, and that means building flexibility into the
process. The word flexibility pops up in everything we do, from packing innovation to product
innovation, and the ability to develop technology
in a master program gets us to deliver on that.
Finally, the process. Work has to be done in

an organized fashion to make it repeatable and
able to be improved upon based on a wide range
of project criteria across the globe. The key elements of that process include capital management, workflow, and governance. But the area
of startup management, which is about keeping
the team engaged from the early stages of
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conceptual engineering throughout the project

journey, is essential to success.
For us it has become a more formal way for
how we approach a project from the start, and
the way we define equipment capabilities and
people capabilities at every stage along the
way. Start early and often on planning in order
to keep people on track, Reed says. n
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Improving Sustainability with Automation

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Improving Sustainability with Automation and Controls

By Rod Emery, Vice President, RedViking
Its easy to think of going green in terms of

facility improvements such as better lighting,
reduced water consumption and treated chemical run-off. We dont usually think about the
impact that automation and controls can have
in conserving energy and natural resources.
But if we consider the way the U.S. Depart-
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ment of Commerce (DOC) defines sustainable

manufacturing, well see that those of us who
design and build automation and controls can
have a big impact.
The DOC defines sustainable manufacturing
as production using processes that:
1. Minimize negative environmental impacts;
2. Conserve energy and natural resources;
3. Are safe for employees, communities and
consumers; and
4. Are economically sound
Each component of a machine consumes
natural resources in its creation and most
require energy to operate. When automation
and controls are designed to include fewer
components, the environment benefits.
Flexible systems are key to this strategy. For
example, single-function exhaust leak testers
each have their own PLCs, pin stampers, bar
code readers, printers and energy consumption. But when these automated systems are
designed to work with a docking station, multiple leak testers can move in and out of a dock
that includes a single PLC, pin stamper and bar
code interface. The leak test system is mounted
on a wheeled base and hooks up to the docking
station with quick-connects. Natural resource
and energy consumption is considerably lower
than with multiple single-use systems.
Capacity utilization can be optimized through
the use of flexible systems, reducing floor space
and power requirements.
We design our assembly line fixtures and
automation to work the same way. Our
battery-free AGVs are designed to accommodate virtually any part with a quick fixture
change-out. The controls that power the AGVs
can also be quickly changed to reflect changes
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to part, process or line path.

Motion control can be another way to conserve energy and resources. While traditional
braking systems can lose 100 percent of their
power in wasted heat, dynamic testing systems
with electrical and mechanical regeneration
recapture up to 80 percent of their power to be
reused in testing.
Automation and controls engineers dont
often think of themselves as agents for sustainability, but we are. By designing flexible,
consolidated, energy regenerating machines,
we can play a significant role in moving our
companies to become greener.
Rod Emery is vice president of integrated
assembly systems atRedViking Engineering,
a member of theControl System Integrators
Association. Visit RedVikings profile on The
Industrial Exchange. n
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Will 2015 Be The Year Of The Robot?

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Will 2015 Be The Year Of The Robot?

By David Greenfield, Director of Content
In the world of automation technology, the past few years
have been dominated by system and device communications
and interoperabilityfrom industrial Ethernet and wireless to
mobility and the Internet of Things. Considering the significant
advances that have been made in this area in both greenfield
and brownfield manufacturing facilities, along with the growing
rate of adoption, I dont see any reduction in interest in these
technologies in the near term.
However, over the past year or so, Ive noticed an increasing amount of news coming out of the robotics sector. Most
recently, I learned of a major investment in Rethink Robotics by
GE Ventures, Goldman Sachs, Bezos Expeditions and a host of
other investment firms. Those firms have allotted $26.6 million
in financing to Rethink Robotics, bringing the companys total
funding to more than $100 million since 2008.
Our new and existing investors recognize the enormous market potential for smart, collaborative robots in manufacturing,
says Scott Eckert, president and CEO of Rethink Robotics.
Industry factors behind these new investments, Eckert says,
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are being driven by the fact that more manufacturers are rapidly
changing the way they do business, prioritizing flexibility and
the ability to turn on a dime when demand or direction changes.
Smart, collaborative robots that can move between tasks seamlessly and have the ability to operate in a variable manufacturing
environment are critical tools enabling our customers to create
the factories of the future.
Backing up Eckerts comments,
George Lee, co-chairman of the
global technology, media and
telecom group and CIO for the
investment banking division of
Goldman Sachs, notes that the
business of manufacturing is
changing more rapidly today than
at any time in recent history [and]
smart, collaborative robotics have
proven to be a significant and
disruptive technology.A recent
example of a collaborative robot
deployment is Schneider Electrics
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use of Rethink Robotics Baxter robot at its plant in Columbia, Mo.

The investments being made in robotics technology are
supported by recent research from PMMI (parent company of
Automation World). In its 2014 Trends in Robotics Market Assessment report, PMMI pointed out that, in its 2008 robotics report,
1 in 5 manufacturing locations used robots and manufacturers
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Mondelez Embraces the Future with

Integrated Control Solution

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and OEMs predicted that robotic usage would nearly double by

2013. Calculating industry data over that time period showed
that actual results outpaced industry predictions, with the use of
robotics on processing and packaging lines, for example, having
more than tripled between 2008 and 2013.
In PMMIs 2014 report, 1 in 5 of the manufacturing locations
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surveyed say they do not plan to use robotic technology in their

facilities in the next 12 months. However, 82 percent of manufacturing locations predict that they will be operating robots on
the plant floor in the next 5 years. This segment encompasses
current users (72 percent) and first-time purchasers (10 percent).
The reasons behind the recent uptick in robotic deployments in
manufacturing, according to the PMMI report, include advancements in vision, programming, software and end-of-arm tooling
(EOAT) technology that allow robots to be more flexible and
capable of moving heavy objects (such as kegs of beer) as well
as handling delicate products and packaging materials (such as
snack food bags).
One of the most significant robot-related trends in the food
industry is the Food and Drug Administration (FDA) approval
of washdown robots and EOAT for use in direct food contact.
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According to the PMMI report, a washable robot has smooth

surfaces that prevent food particles from gathering on the
surface and an EOAT that can be chemically sanitized to make it
aseptically clean. With the approval of washdown robots for food
handling, robots are poised to quickly move upstream to processing and primary packaging operations.
Many of the reasons cited in the PMMI report for the increased
interest in robotics are addressed by Rethink Robotics Baxter
which, with its various EOAT options, can be used in kitting,
packaging, loading/unloading, machine tending and materials
handling applications.
Click here to see a promotional video from Rethink Robotics that
highlights how Baxter is being used in collaborative robot/human
operations at Praxis Packaging. n
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Mondelez Embraces the Future with

Integrated Control Solution

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Mondelez Embraces the Future

with Integrated Control Solution
By Jim Parsons, Contributing Editor and Pat Reynolds, VP Editor of
Packaging World
Ask any packaging system owner to come up with a wish list of
things that would help improve the quality of their operations,
and its likely that information will rank near the top.
And no wonder. Information, after all, is the cornerstone of
21st Century productivity and profitability. Its what helps system
owners identify, plan, and validate system improvements and
changes; benchmark performance against overall equipment
effectiveness (OEE) and other goals; and spot opportunities
to eliminate inefficiencies, even the most minor of which can
undercut a well thought-out continuous improvement initiative.
Todays controls systems and associated infrastructure can
provide packagers with all that informationand moreon
virtually any aspect of system performance imaginable, from the
individual machine to across the entire enterprise. To get it, all a
packager needs to do is ask.
Access to all that quality informationand moreis at the heart
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of the plans for Mondelez International to completely re-engineer its

packaging lines, part of the Deerfield, IL-based snack food manufacturers global transformation of its manufacturing platforms.
Having adopted the Integrated Lean Six Sigma approach to
process improvement company-wide, Mondelez International
relies on information to ensure that new equipment and technologies that will be integrated into new processespart of an
ongoing project called the Line of the Futurewill fulfill their
intended objective of driving out waste and inefficiency while
also bolstering the quality and productivity necessary to increase
their gross margin and foster further growth.
Werner Badtke, Program Manager for Automation and Manufacturing Systems at Mondelez International, uses the streamlining of
the companys process for baking the popular Oreo cookies as an example of one way the company is reinventing its global supply chain.
Recipe and process changes enable us to eliminate major
components, such as a 60-meter long cooling tunnel, Badtke
explains. That results in a machine with a smaller footprint, and
a more flexible set-up.
NEXT
Opportunities and constraints

The companys ambitious objectives for its Line of the Future
program are not unlike those of other CPG companies seeking to
optimize the OEE of new and existing lines. Not surprisingly, it also
shares some of the same implementation challenges when integrating smart machines into a smart manufacturing environment.
One of the biggest challenges revolves around performance
management integration with and among the Line of the Futures machine elements. Each major component of a packaging
line has its own performance story to tell, which is defined in
part by the packagers line-, facility-, and/or enterprise-specific
OEE data requirements, and the control technology being used.
Timing benefitted Mondelez International, as planning for
the Line of the Future coincided with the emergence of PackML,
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enabling the company to match its requirements against the

capabilities of the open-source control programming standard.
Despite PackMLs programming efficiencies, however, sequencing a lines operation and inter-machine control to meet these
requirements nevertheless requires custom coding during the
integration process.
While integrators can reuse bits and pieces of code, and utilize
repeatable engineering tools to help expedite the line integration process, its still necessary to understand how machines
have been programmed and then configure how the line needs
to run, as well as determine the best way to collect and process
OEE data. While PackML closes the gap, it doesnt give you OEE.
All of this, of course, requires an investment of time and effort
a factor that didnt exactly fit with the vision Mondelez International has for an expedited worldwide roll-out of new, highly
flexible packaging lines in a connected-enterprise environment.
Indeed, while the company has relied on standard designs for
its lines, product- and facility-driven deviations that incorporate
singular characteristics caused delays in startup and drove up costs.
To ensure the Line of the Future avoided those shortcomings,
the company needed a cost-effective solution that provided per-
Sponsored by
formance management and line control in a standard yet flexible

solution from the outset.
We wanted vertical start-up support for new lines that could
be implemented using a copy/paste approach, Badtke says, one
where a copy of an existing system could be implemented quickly
and easily by pasting it into a partially installed or configured
system, making the implementation process easier and less prone
to mistakes with each new addition. And we needed full support
for what would be a global implementation, Badtke adds.
Expediting a transformation
That may sound like a tall order for any solution to fulfill,
which is why Mondelezs search for a suitable answer spanned a
wide range of OEE reporting software packages, including those
already in use and others that had appeared on the market.
The platform it selected uses a common equipment interface
based on PackML/ISA-88 standards, which enables users to
configure, control, and analyze line performance from a standard
operator station, thereby reducing the total cost and time of deploying and optimizing packaging lines. Whats more, its built-in
OEE reporting capability eliminated the need to incorporate ad-
NEXT
ditional reporting software after the line is set up. It represents a

major departure from the traditional approach of integrating the
line control first and the performance management later.
The platform didnt supersede or eliminate the integration
process, but it provided a faster, easier way to integrate projector user-specific specifications. With enhancements specified by
Mondelez International, the platform was adopted as the companys global line integration standard for the Line of the Future.
Its not only a software package, its a full concept that is able
to vastly simplify and standardize line integration, says Badtke.
You have a supervisory system that consists of a server, a client
view, and a performance view, which means you have all the
information necessary to collect into reports. Theres no need for
a programming tool. Its completely plug and play.
Rather than going through the process of writing new PLC
code to establish machine-to-machine communication for each
line, the software allows the end user to set up each lines supervisory control structure via an HMI, automatically incorporating
the appropriate PLC code for selected data block definitions and
applications, such as line balancing, equipment recipes, changeover coordination, or energy management.
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Its more of a configuration exercise with check boxes than

integration, which eliminates a lot of custom PLC modification
work, says Badtke. The machine is there or its not. You type in
its properties and what you want it to do for each product it runs,
and the PLC is coded accordingly.
Badtke adds that users also can perform dynamic event
configuration for each PackML status for a machine, and how it
affects others in the line. For example, he says, you can define
what one machine should do if the downstream machine is
faultedstop immediately or after a few minutes.
Then, of course, theres collecting and managing that allimportant performance information. Because RAPID facilitates
the collection of vast amounts of PackML status data, Mondelez
International can compare OEE for a particular product on multiple machines across multiple days and/or locations, providing a
more comprehensive analysis of machine and line performance
over a specified period of timestatus changes and durations,
fault causes, and other function-critical statistics.
Badtke cites a software-generated pareto chart of down times
as being especially helpful to the 80/20 approach that is central
to the Six Sigma initiative at Mondelez International.
Sponsored by
This information helps us more easily identify and focus on

resolving the faults representing 80 percent of the downtime,
which are considered more critical than the minor faults that
account for only 20 percent, Badtke explains.
Similar to providing a standard approach to line integration,
the software provides a standard set of production management
capabilities that makes it easier for the line to exchange data with
and take orders from a new or existing management execution
system (MES) and enterprise resource planning (ERP) software.
Scheduling functions, such as the order of products or downtime
for cleaning, can be issued without having to make any changes
to the line control because its all modeled, Badtke. The lines can
receive a packaging order to produce a specific amount of a specific
product during a specific period. The software does the rest.
Badtke says the company is currently considering other
enhancements to the system to deploy new Lines of the Future.
We want a system that will provide the best complement for
our cut and paste approach to deploying new lines, he says.
Building momentum
Mondelez International plans to implement its Line of the Future
NEXT
concept for a variety of product types at both existing and new

facilities. The lines are already in operation in a number of cities.
Badtke notes that while this approach offers great value
to the Line of the Future, it doesnt require an all-or-nothing
commitment for the companys long-term growth strategy.
Because there are always exceptions when it comes to facilities
and products and packaging equipment, the company plans to
keep its options open when considering controls technologies
for new projects. Where there are specialized requirements
involved, the project leaders or the plant can decide whether to
use a different standard.
That approach gives Mondelez International the best chance at
realizing another common, coveted attribute on every packagers
wish-list: flexibility to meet the demands of an ever-changing,
highly competitive marketplace.
Its all part of a continuous cycle, whereby leveraging a common, simple technology platform will help us save money, which
can then be reinvested in growth to help us focus on our power
brands and priority markets, Badtke says. Were confident this
approach will be instrumental in helping us achieve our business, operational, and quality goals. n
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Flexible manufacturing is, in its essence, the capability of making different vehicles on the same
assembly line without long delays to change
tooling. In practice, it is now possible to make
completely different vehicles on the same line
with no delays to change between vehicles.
The way this works is by extensive use of
robots and computers; the robots have tooling
or spot welders on the end of their arms and
when a new vehicle comes down the line,
Sponsored by
they can quickly swap to different tooling

or welders, and apply their arms in different
ways. This also works in the paint shops, where
robot arms are programmed to act differently
depending on the vehicle that shows up.
This requires more flexible robots with
computerized programming and networked
communications, which is one reason why
flex manufacturing was not practiced much in
the 1990s (when cars were assembled almost
entirely by hand, flex manufacturing was also

possible and was moderately common, but it
could easily lead to quality gaffes, where the
wrong parts were applied e.g. Dodge labels
to Plymouth cars or mismatched right and left
side mirrors).
In addition to network communication, barcodes or RFID (radio frequency identification)
tags can be used to tell the machines what
model is coming down the line.
The primary requirement for using flexible
manufacturing is the ability for different vehicles
to use the same carriers (or having multiple
carrier types. There are usually four points
where the carriers carry the body until tires are
installed, and the vehicles is put onto a flat track.
If these points are carried over from body style
to body style and there is enough clearance in
the carrier (or in the case of welding, you have
the jigs and end tooling for the part) you can
produce many different models and styles.
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Platforms are defined as common dimensions between various top hatsand architectures(collections of hard parts), so that
various completely different vehicles can be
built within the same physical space allotted to
the vehicle carriers.
You have to see a flexible body shop in operation to truly appreciate the advantage over the
old style body shop. You do away with those
large fixtures or jigs that could only assemble
one part/vehicle each. With flex manufacturing
a robot can be programmed to assemble and
or weld say a Caliber quarter panel followed
immediately by a Compass quarter panel, then
a Patriot quarter panel.
One robot can hold the part while a second
welds the piece even if the part is in motion. You
can build completely different vehicles sharing the
same architecture, one after another, with just a
programming change. Robots are strong enough
now to handle an entire body at full reach.
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Pneumatic Valve Terminal

22 / 31
When the new model changes, the software

is simulated and then downloaded to the
plant-floor robots with no need for expensive fixture rework or replacement. Chrysler
employees can do robot motion simulation
without ever seeing the actual part/vehicle in
the flesh. The CAD files are used to assemble
the vehicle on your computer and run the
simulation at your desk.
Some of the advantages:
Competition has greatly increased, and while
Sponsored by
100,000 units are still needed to recoup

engineering expenses, its harder to sell that
much of a single vehicle. Creating multiple
models lets more designs/vehicles can carry
the load (and reduces the risk of a single bad
styling decision bankrupting the company).
So as long as the numerous vehicles on that
platform can total 100,000 units in sales in a
year, the goal (and costs) are met.
Flex can allow vehicles that arent completely similar (differing wheelbases, num-
ber of doors, etc.) to be built on the same

line without stopping production to change
out tooling - the tooling accommodates the
vehicle instead.
Once a vehicle is design to take advantage
of the flex system, the time it takes to get
that vehicle to market is reduced.
Should one flex vehicle take off in sales,
the number of those vehicles produced can
be adjusted on-the-fly.
If one vehicle really takes off, that vehicle
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can be built in another plant that supports

that flex. For example, lets say the Avenger
becomes incredibly popular. They could build
more of them at the Caliber/Compass/Patriot
plant, because the flex systems are similar.
The investment in flex was started long ago;
this isnt just some new-fangled thing. We are
just now seeing the fruits of those investments
coming to light. n
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The compact, low-cost VTUG pneumatic valve terminal from Festo
offers flexibility in the choice of control options, including simplified field bus connectivity, and many other performance benefits
for machine builders and end users in high-volume industries.
The VTUG is designed for food, beverage, packaging, electronics,
semiconductor, and light assembly industries where low cost and
assured performance (high flow rate, small footprint, and long
cycle life) is essential. Compact, lightweight VTUG aluminum manifold and valve housings can be mounted in cabinets, on machines,
and on robotic end effectors. The VTUG valve terminal is also ideal
for compact pilot valve applications when using an available dual
3/2-way function valve to accommodate from 4 to 48 solenoids.
The VTUG is said to be ideal for the machine builder that wants
to standardize on one valve terminal and offer customers control
options from conventional multi-pin up to fieldbus. The original
VUVG design, introduced in early 2011, included the E-Box
approach for electrical connectivity, allowing users to stock one
valve body and choose from many designs to match application
needs. Each E-Box uses a different electrical connector (such as
Festo connectors, standard M8 connector, and other choices).
Flexible design philosophy allows the user to select a desired
Sponsored by
communication preference for the VTUG valve terminal and

modify it in the future. The VTUG valve terminal can be controlled
through a multi-pin connector, one cable IO-link interface to a
master controller, or through Festos new CTEU fieldbus module
to DeviceNet, EtherCAT, CANopen, Profibus, and several other
protocols. Multi-pin and I/O link modules are available as spare
parts to easily convert existing valve terminal configurations,
ensuring flexible communications.
VTUG is Festos most cost-effective and simplest to apply universal valve manifold. The company reduced costs by using the
latest technology, design concepts, and production techniques
from existing valve series, such as the VUVG. Each valve body
shares similar internal VUVG designs so the same tooling can be
used to produce both valve types. The valves also share the same
cartridge seal design, common to many Festo valves. Finally,
solenoids used were taken from Festos existing VTOC valve line,
all adding to greater economies of scale.
Cartridge seal design allows for reversible operation, twopressure operation in one valveone valve can produce a vacuum
and positive pressure for greater flexibility. Cartridge seals design,
proven in other products, has demonstrated a long service life.
NEXT
Terminal design simplifies modifications, replacing faulty

valves or exchanging existing valves for those with other functions. Using a captive screw design and defined gasket compression makes the exchange of valves simple and low risk. Unique,
self-locking plugs can be set in the manifold to enable on-the-go
pressure zone modification.
These valves are suitable for low- and high-pressure operation, up to 10 bar. High pressure minimizes the size of actuation
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24 / 31
cylinders. Smaller cylinders reduce overall cost and improve

compressed airflow, increasing machine performance.
Festos integrated current reduction technology lowers overall
energy consumption and enables 100% duty cycle performance
by decreasing current draw after the first few milliseconds the
solenoid is energized. Another benefit of reduced current draw is
that less heat is generated within the valve, to extend service life.
Sponsored by
An air spring return system (instead of mechanical spring) provides

for a more balanced overall switching time within the valve and decreases production costs by eliminating the need for wearing parts.
Festo claims the new VTUG from Festo proves to be one of the
most economic and reliable solutions for high-volume applications
where performance is required, but cost effectiveness is key. n
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New materials and the drive for greater flexibility in
production have created new challenges in handling
Improved capability
Lightweight trend
Focus on flexibility
Multi-model lines
Long-term view
spot. Equally clear to see are the tensions and trade-offs that
exist between them. The inexorable march of automation, for
instance, drives productivity upwards and unit vehicle costs
downwards, but in plants striving for flexibility and mixed-model manufacture, ill-considered automation imposes constraints
that make such objectives more difficult to attain.
Similarly, the push towards lightweighting sees manufacturers adopting newer, lighter materials. The downside being that,
more easily damaged, such materials require careful handling
which can drive up equipment costs while acting as a drag on
cycle time reduction.
NEXT
from the equipment they buy faster cycle times, faster set-up
times, higher throughput, greater flexibility and shorter delivery
times, says Martin Sahlman, product manager for automation
systems at press and automation specialist AP&T. For us, that
means modular construction, fewer components and a requirement to produce and deliver the equipment quickly.
Suppliers engaged in materials handling are tasked with
quickly and efficiently bringing parts together at the applicable
station in the shortest possible cycle time, then just as efficiently
moving them on to the next stage in the assembly process.
So what trends are automotive materials handling companies
seeing, and how are they responding?
Improved capability
Walk through almost any modern automotive assembly plant

and the major trends in automotive assembly arent difficult to
Sponsored by
Talk to the companies that serve as the automotive industrys

equipment suppliers and these tensions and trade-offs are evident. At the forefront of designing, building and delivering the
machinery that turns aspiration into factory floor reality, they
typically supply the equipment that actually touches the vehicle
or its major components; gripping systems, robots, conveyor
systems, and automation and control systems.
All the automotive OEMs are demanding greater capabilities
Lightweight trend
As materials handling insiders make clear, the industrys
longstanding drive for improved productivity and lightweighting
is still throwing up new twists.
Craig Kenhart, industry segment manager for automotive
belting system manufacturer Habasit, for instance, points to the
enhanced use of people-mover conveyors in assembly plants, allowing workers to travel with vehicles as they are being assem-
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Lab Innovation Based on Toy and Material

Handling

26 / 31
bled. Such systems, notes Kenhart, have been shown to increase

productivity, reduce worker injury and decrease rework.
Forget people-movers constructed from traditional heavy rubber conveyor belts containing steel cord members, he stresses.
Today, it is modular or fabric-based people mover belts that
are finding favor. Pointing to advantages such as low energy
consumption, due to the low coefficient friction of the reverse
side; a belt-edge safety signal (belt edges can be equipped
with yellow colored modules); and non-slip belt surface profiles,
Kenhart says that Habasit works closely with automotive OEMs
and conveyors systems suppliers to advance what is possible.
Belting to address the different load levels that can be found
with people-movers is available, as well as belts with specific
material features such as anti-static, electrically conductive and
flame retardant, adds Kenhart. Were seeing increased demand
for people-mover installations in the traditional automotive
production locations, as well as in the growing markets of China,
Russia, South East Asia and South America.
Lightweighting, too, is throwing up new considerations. As
well as the materials traditionally used as steel substitutes
plastics and plastic-based composites aluminum is finding
Sponsored by
favor, says AP&Ts Sahlman. While lighter than steel, its a lot
softer, which has a bigger impact on the associated material handling equipment, he points out. Not only does that
mean you have to have handling equipment that doesnt cause
scratches, it also means that you need a cleaner, more hygienic
environment, avoiding production debris.
Focus on flexibility
Even so, the big story is flexibility, with automotive OEMs replacing single-model factories with assembly plants, which can
NEXT
handle multiple models, changing the mix of production based

on sales and customer demand.
Moreover, ambitions are high. Ford, for instance, has not only
moved the majority of its plants to multi-model manufacture,
but has stretched the envelope of what multimodel can encompass. Its Flat Rock, Michigan plant has recently been re-tooled for
the 2013 Ford Fusion mid-sized sedan alongside Ford Mustang
production two models that could hardly be more different.
The overarching trend in automotive assembly is the flexibilization of assembly lines, which calls for equal flexibilization
of the associated materials handling technology, says Werner
Reichelt, head of the automotive industry segment at gripping, clamping and drive specialist Festo. Were seeing other
requirements such as advances in energy efficiency and safety
technology but flexibilization is the major one.
The drive for flexible manufacturing is probably the biggest
trend in the industry right now: building multiple models in
plants that might not have done that before. Its driving a lot
of process change in vehicle assembly plants, as well as posing
space utilization challenges. Its one thing being multi-model,
and quite another being multi-model within the same footprint.
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The same picture is seen at vacuum handling specialist J.

Schmalz, adds Jochen Gunkel, head of the companys automotive
industry group. German and Japanese manufacturers are concentrating on creating flexible platforms on which they can build
as many vehicle models as possible, he notes. For us, that means
developing flexible and universal gripping systems, capable of
delivering parts at a high rate of production, and with suction
cups that can grip even at high rates of speed and acceleration.
Multi-model lines
At Festo, meanwhile, the push for flexibility has seen the business move out of its core niche as a pneumatics supplier. Originally, we were a pneumatics supplier, but increasingly we have moved
into electro-mechanical devices and actuators, as well as a turnkey
design and build service, says Reichelt. This helps our automotive
partners and automotive machinery manufacturers achieve their
flexibilization goals, and produce more vehicles on the same line.
For every pneumatic cylinder in Festos range, he explains,
today there is almost always an electro-mechanical direct equivalent, driven by a servo motor. If you need very, very precise
positioning, its difficult to achieve that with pneumatics com-
Sponsored by
pressed air has an element of springiness to it, explains Reichelt.

For real precision, you have pneumatics on the Z-axis, because
its lighter and cheaper, and electro-server electro-mechanical
devices on the X- and Y-axes, where you need the precision, in
order to precisely grip the parts in question. In other words, you
need both technologies to get an efficient, flexible solution.
The automotive industry is recognizing this, Reichelt adds.
Already specified as the standard sole supplier at BMW, and the
predominant supplier at Daimler, Festo is seeing other automotive OEMs pushes into flexible multi-model manufacturing play
to its strengths.
Were growing our market share at Ford and GM, where our
capabilities have now been added to these manufacturers internal engineering specifications, says Reichelt. Traditionally, the
engineers specifying pneumatics have been different from the
engineers specifying electromechanical equipment now they
are coming together, which helps us.
A similar message comes from overhead conveyor system specialist OCS Overhead Conveyor Systems, with the drive for multimodel flexibility making itself felt in demand for a new generation
of overhead carriers, says area sales manager Jan Erik Karlsson.
NEXT
The goal is not only to develop a product carrier to deliver

the best ergonomic solution, but also enable customers to get
as many functions as possible in the same carrier, he says.
This avoids bottlenecks in the assembly line and means that
the product can stay in the same carrier from the start position
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through kitting, assembly and testing, and will finally reach the
unloading point at an exact and controlled cycle.
Long-term view
That said, while the push for multi-model flexibility is the
overarching trend, materials handling suppliers are also seeing
a similar demand for flexibility in how they actually deliver the
solutions that they offer in response.
Automotive OEMs have moved from a payback mindset seen
in terms of individual projects, to a longer-term view of their
requirements, and acquiring functionality which they will be
able to use over that longer term, says AP&Ts Sahlman.
Sponsored by
There are also shifts in both the size of equipment and the underlying philosophy of equipment control. Instead of one big controller
controlling multiple stations, automotive OEMs want distributed
control and smaller and more flexible controllers. This gives them the
flexibility to move work around, and re-balance the line dynamically.
From a software perspective, theres a much tighter integration
between the plant floor manufacturing execution system, the
business system and the individual controllers. The software has
to be far more flexible, and capable of handling more functions.
Back at Schmalz, Gunkel doesnt hesitate to point out the
reliability implications of equipment that is more complex as
well as smaller, more distributed and more flexible than previous
NEXT
generations as well as capable of producing at higher output

levels. For us, that means adding predictive maintenance and
condition-monitoring technologies to our existing vacuum pump
and vacuum handling solutions, which means that the product
includes more electronics, he explains.
Gunkel continues: The idea is to be able to predict failure that
would cause downtime, and alert the operator in advance and
to do so, whats more, without requiring the operator to enter
the robotic cell doing it through SCADA and PLC systems.
In short, the requirements in automotive assembly are changing
rapidly, and the good news for manufacturers is that so too is the
materials handling industry that is supporting that change. n
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Lab Innovation Based on Toy and Material Handling

By Sam Stoney, Senior Project Engineer,
Life Sciences, Festo
Every square foot in a laboratory costs money. Lab automation

OEMs take this into account by designing their equipment to
handle smaller sample sizes, increasing the functionality of each
piece of equipment, and by reducing the overall footprint of their
products as much as possible. When Zinsser Analytical GmbH
began developing a new sample handler for collecting fractions
(very small chemical samples prepared for liquid chromatogra-
Sponsored by
phy), the company sought out automation design advice to see

how small things could be.
The issue Zinsser was looking to address was a need to transfer
very small quantities of liquids into 96 or 384 well microplates
in a minimum amount of time. To reduce the potential for cross
contamination in this process, the platform holding the microplates would be positioned under a non-moving liquid dispense
system. This idea differs from the more common industry practice of moving liquid handling arms over the sample plates.
To meet optimum design criteria for this idea, as much of the
unit as possible had to be easily accessed from above. In addition, the system needed to occupy a minimum footprint. As for
operation specifics, the equipment also needed to process up to
10 plates automatically. This spec required that a plate stacking
system be integrated into the design.
The answer to this new laboratory automation design came
from the flat-panel TV handling market. Engineers at Festo, the
automation company Zinsser Analytical collaborated with on this
design, drew upon a two-axis gantry concept used in a product
Festo originally designed for flat-panel TV handling. The x-y gantry utilizes a single belt driven by two motors in series to control
NEXT
both axes, thereby reducing both size and moving mass. The end
result is a product known as the FRACS.
Functionally, the design concept used in the FRACS has been
around since at least before the Etch-a-Sketch, but Festo took
the single belt x-y control design and turned it into a standard
automation product.
Mounting the belt to a single point on the stage and driving
it via pulleys on the two motors results in the same kinematics as the Etch-a-Sketch toy - when both motors move in the
same direction, the slide moves in the x axis; when they rotate
against each other, the table moves in the y direction. The design
allows both motors to be stationary, thereby simplifying wiring
runs, reducing size and mass, and lowering the total number of
components needed in the system.
By scaling the unit down to a single extruded plate and
designing the motors and controller to fit beneath the extrusion,
Festo created a full 4 x 6 inch working area in a package slightly
larger than 9 x 10 inch and only 4 inch thick. The compact design
of this Mini H Gantry allows supply lines for fluids, pressure
or vacuum to be made shorter. Motors in the system work in
series; doubling their torque output to achieve fast acceleration/
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Additional References

30 / 31
deceleration for optimum positioning time while maintaining a

positioning accuracy of .004 inch.
With the H Gantry as the core of the design, there was plenty
of room for the mechanics of the stacking and de-stacking
systems using a combination of standard Festo electric and
pneumatic actuators under the table.
Sponsored by
NEXT
The design also has promise for other areas of lab automation,
as well as in other applications requiring fast, precise x-y control
in a small area. Festo has since taken this concept and is developing a full product range of two-axis positioners with working
areas of up to 12 x 24 inch, higher precision versions, and with
servo or stepper control options. n
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Additional References
Integration simplifies machine safety
How new safety standards and technologies can make workers safer and plants more productive
Additional Flexibility References

Siemens and Festo win Optima as a pilot customer for innovative transport system
http://www.siemens.com/press/pool/de/pressemitteilungen/2015/digitalfactory/PR2015030168DFEN.pdf
http://www.drivesncontrols.com/news/fullstory.php/aid/4770/Linear_motors_power_flexible_machinery_transport_system.html
Flexible Manufacturing Systems
http://www.referenceforbusiness.com/management/Ex-Gov/Flexible-Manufacturing.html
Packaging World Flexible Packaging Playbook
http://www.packworld.com/playbooks/flexible-packaging-playbook
Sponsored by
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Laboratory automation made easy

Solution installed on a mounting plate or

integrated into a handling cell with clear interior and

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

The basic handling system consists of:

Flexible configuration of the handling solution for small workplaces.

Mini slides EGSI, EGSK or the linear gantry

Today a concept, in the future a worldwide standard

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

Serving with high positioning accuracy

The best example of the high speed delivered by Robot Food

Automatic Tool Changer

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

work with this supplier. We export 80% of the machines we sell.

Automatic Tool Changer

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

Automatic tool changer

al requirements. These include, for example,

Progress with a tiny

The principle of the automatic changing

The central interface

tool changer and means it can be fitted directly

Vacuum Tooling Reduces Changeover Time

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

Interview: Trends in Automation

converted and adapted to the required functions. On the front

Low consumption, high availability

Gerhard Schubert GmbH

Vacuum Tooling Reduces Changeover Time

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

Vacuum Tooling Reduces Changeover Time

put eight different manifolds on the end-of-arm tool, bringing

Kelloggs Quest for Manufacturing

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

one for each manifold. Also on the end-of-arm

nance interactions with the valve controls.

Kelloggs Quest for Manufacturing

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

Kelloggs Quest for Manufacturing Innovation

be different metrics and scale related to brand

Its also always important to keep money in

end, instead of adjusting the previous years

Improving Sustainability with Automation

Flexible Manufacturing Solutions: The Key to Boosting Your Productivity

allows us to take on a lot of new projects that

Knowledge management also becomes critical

Finally, the process. Work has to be done in

Level 1: basic handling system on a