by F.S.
The Turnkey FlexLine in action for chocolate teacake application: the box forming and the box closing with easy and quick change over. It’s a matter of hygiene, product care and accuracy.
(video: Cama Group)
Human-centered approach, Industry 5.0 industrial ecosystem
Man-machine interaction is emphasized in Industry 5.0, highlighting human talents, innovation, and problem solving. Human intervention in complex decision-making processes is recognized and the integration of human creativity with technology is suggested.
“This is our long-term approach; our intelligent machines have human-machine interfaces, communicate with one another, and are controlled by humans via an operator panel, just like a smartphone or tablet.” Massimo Monguzzi begins. “We put the man in the center, and we’ve been doing it for a long time.” We developed and implemented the most immersive and inclusive human-machine interface available. The interface connects the human mind with machines, and in the future will be inextricably linked to artificial intelligence, an essential production factor that aids the human in the improvement of the production processes that he must manage.”
While Industry 4.0 paved the way for Machine-to-Machine systems, Industry 5.0 focuses on human-machine collaboration, envisioning a workplace where humans and machines coexist, but where are we going?
“We can predict that automation will continue to grow. An autonomous and intelligent machine is no longer sufficient; an ecosystem that incorporates people is required. To do this, instruments such as artificial intelligence, which, along with technological systems for automation, are already available in our machines, are required.”
What should a sustainable production environment look like? Technology helps us
Industry 5.0 emphasizes the importance of sustainability: it creates new opportunities while reducing the environmental impact of production operations. What tangible influence does a tool such as Cama’s Digital Twin have on sustainability?
“The Digital Twin is an efficient and easy-to-use tool that is integrated into Cama systems; it replicates a production process before it is put into practice. By doing this, we are able to avoid wasting time, materials, and resources on production tests. It reduces the length of the design and allows for a lot of flexibility, well aware of how crucial this is to handle the fluctuating demand”. Massimo Monguzzi adds, “With the help of the Digital Twin, we can assess the effect of the selected solution among the numerous choices on objective data.
“A concrete example is a machine displayed at the interpack show with an integrated pick and place solution developed using the simulation-based engineering concept. What does it mean? The simulation enables us to make exact design decisions that are not only structural, as in the past, but also functional, based on performance reasoning. Indeed, operation can be simulated from the design process to validate the best decision between several alternatives: performance and lower environmental effect. In this case, a grip using vacuum technology was required; initially, we thought of a safe solution with a seven-position gripping system for each robot, but with the simulation, we realized that it would have been better to work with a four-position robot and one with three thanks to the Digital Twin; in this way, we halved consumption overall energy efficiency of the plant and we can do it for the entire life of the machine on a continuous cycle of 24 hours a day. In addition to production sustainability, we consider areas that are essential to us, such as ergonomics in machine use, easy to use, conveniently accessible, and safe in all operations such as loading-unloading, cleaning, and maintenance.”
Sustainable customization with “On-the-Fly” format changeover
Industry 5.0 recognizes the growing demand for customized products, for which packaging technologies that use artificial intelligence in conjunction with big data are deployed, customizing the packaging to the tastes of individual customers while also preventing food waste during manufacturing activities.
“The “On-the-Fly” format changeover was designed and realized on the line displayed at Interpack 2023 for the chocolate sector, allowing for continuous production. As production progresses, you can move from one kind of packaging to another”. Massimo Monguzzi describes the alternative method as “a very interesting one that goes beyond the conventional one that would have resulted in a stoppage in the packaging plant for format changeover with significant food waste produced during the interruption of the packaging phase. In this case, the chocolate must be placed in the box or packaged single or double. What happens when we must switch different formats? With our system, you may move from a box format to a single or double wrapped format “On-the-Fly” without interrupting production. Indeed, if the secondary machines have a problem and have to stop for a longer period of time than the minimum, output will be automatically redirected towards the single-piece format.”
Format changeover “On-the-Fly”. Is it just related to this line?
“Regards all machines for which a comparable production layout has been configured. In this instance, it is for the chocolate industry, but it may be made for other industries as well. If I have two parallel lines and one should stop for any reason (format change, for example), the other active line might produce an excess; if it can make up for the stopped one, all the better; if not, we could experience a temporary slowdown but not a stop, preventing any product waste during production.
For the fruit juice industry, a conceptually similar plant has also recently been developed with multiple machines connected in series; if one were to stop for a format change, this would happen in blocks so that the plant would never be unproductive; however, it is set up for an incremental format change, where I would start from one zone and then another would follow without ever interrupting production”.
Global collaboration and connectivity
Industry 5.0 emphasizes cooperation and connectivity by expressing a world in which enterprises, suppliers, and customers may collaborate using the Internet of Things and the power of digital platforms. “In comparison to traditional PLC controllers dedicated to data collection, our machines have integrated solutions with additional PC-based devices. Man-machine interaction, data processing, transmission, and cyber security are all solutions built into the machines on which Cama has been working for some time.“
Future of industry and automation ethics
The move from Industry 4.0 to Industry 5.0 should be gradual, with overlapping characteristics and ideas. The major goal of Industry 5.0 is to humanize technology and create the most ethical, sustainable, and inclusive manufacturing ecosystem possible.
What will the future of the industry look like in terms of technology?
“Artificial intelligence will be a key component, powering many applications that will need to be increasingly flexible in production. Robotics will use high-performance vision systems to assist manufacturing equipment in optimizing operations. Machines will be able to enhance themselves by learning how to maximize their performance wisely. All of this will be enabled by digital platforms that analyze data and allow machines to adapt to different applications.“
How to protect connected industrial machines?
Cyber security for connected industrial machines is of the utmost importance because it protects production infrastructures from cyber-attacks and ensures their integrity by avoiding unauthorized access, data breaches, operational interruptions, and potential security issues. Digital security goes hand in hand with artificial intelligence, which, while bringing amazing productivity benefits, also necessitates a high level of attention and protection.
“When we consider how important IT technology is today in the industrial world, we are dealing with an issue that is still underestimated. The European Union has currently issued a machinery regulation that contains issues connected to cyber security but has not yet been applied by the individual states,” Monguzzi clarifies.
“The industrial production chain is extremely valuable, and any unanticipated downtime results in economic loss as well as the loss of confidential and strategic brand information. It is now obvious that the value of information and data is linked to the value of the product. Producers are aware of this, and the industry is beginning to take a stronger care of it.“
