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AMPC's 2030 Vision for Modern Manufacturing
- 2. 2 Modern Manufacturing - AMPC’s 2030 Vision
- 3. 3 Australian Meat Processor Corporation Our Presenters 1. Chris Taylor – Chief Executive Officer 2. Sean Starling – Senior On-Plant Innovation Manager 3. Stuart Shaw – Program Manager (Advanced Manufacturing) 4. Matthew Deegan – Program Manager (Sustainability) 5. Greg Williams – Co-Innovation Manager 6. Amanda Carter – Program Manager (People & Culture) 7. Jemma Harper – Co-Innovation Manager 8. Matthew O’Bryan – Senior Program Manager (Integrity) 9. David Dwyer – Co-Innovation Manager
- 4. 4 Australian Meat Processor Corporation • Processor research and development corporation • Statutory levy and government matched funding • 106 processor members • Skills-based board from industry Here for Processors
- 5. 5 Australian Meat Processor Corporation • Bovine, ovine and caprine • Diverse throughputs • Different innovation needs • Different innovation support options Processor Innovation
- 6. 6 Australian Meat Processor Corporation Why Innovate? • Part of a thriving value chain • Highest cost to operate globally • How to attract and maintain a strong workforce? • Can we be safer at what we do? • Global push for enhanced sustainability
- 7. 7 Australian Meat Processor Corporation
- 8. 8 Australian Meat Processor Corporation
- 9. 9 Australian Meat Processor Corporation
- 10. 10 Australian Meat Processor Corporation
- 11. 11 Australian Meat Processor Corporation
- 12. 12 Australian Meat Processor Corporation Stuart Shaw & Greg Williams • Shadow Robots • Gamification • Magnetic Conveyors • Industry 4.0 – Sensors/Artificial Intelligence/Machine Learning Program One Advanced Manufacturing
- 13. 13 Australian Meat Processor Corporation Shadow Robots • Full automation is limited by: • Sensing and Visioning systems • Material handing • Semi-automation • Humans controlling robots • At line, in control rooms & from home Aspirational Vision 2030 – No hands on cutting Video source: https://www.youtube.com/watch?v=3rZYn62OId8&t=6s
- 14. 14 Australian Meat Processor Corporation Gamification • Semi-Automation • Increase employment demographics • Increase appeal of the industry • Undertake operations remotely Aspirational Vision 2030 – Uber operators
- 15. 15 Australian Meat Processor Corporation Magnetic Conveyors • Cars are to horses as • Magnetic Conveying to Conveyors • Benefits: • Traceability • Reduced maintenance • Flexible manufacture Aspirational Vision 2030 – Remove FIFO limitations Video source: https://www.youtube.com/watch?v=wCj1kJ1Fyk4
- 16. 16 Australian Meat Processor Corporation Industry 4.0 • Understand I.4.0 benefits to processing • Evaluation of: • IoT sensors • Artificial Intelligence & Machine Learning • Digital Twins • Additive manufacturing Image source: Unknown
- 17. 17 Australian Meat Processor Corporation IoT – Wireless • What sensors are available? • Are they processing robust? • How is the data analysed • What is the CAPEX / OPEX? • Output = Best applications Image source: https://sensoteq.co.uk/ Aspirational Vision 2030 – Critical equipment monitoring Video source: https://www.youtube.com/watch?v=HyPMyFHViTU
- 18. 18 Australian Meat Processor Corporation Program Two Matthew Deegan & Greg Williams • Water Recovery • Biomass Energy Generation • Trade Waste pond evaluations • Services Monitoring Sustainability
- 19. 19 Australian Meat Processor Corporation Water Recovery • Reducing water intensity is a high • Processors reduction by 9% since 2009 • Next big challenge - advanced water recycling • Pilot will help build confidence & capability • Containerised MF-UF/RO has filtration choices • Objective is Low-cost Class A recycled water Image source: https://www.newfoodmagazine.com/news/134711/unilever-container-factory/ Image source: MAK Water Aspirational Vision 2030 – 90% advanced water recycling
- 20. 20 Australian Meat Processor Corporation Biomass Energy • Combustion of fossil fuels is hardest to abate emission • Future cost & reliability of fossil fuels is under threat • Build confidence & capability in renewable fuels • 1MW pilot will provide a multi-fuel biomass boiler • Multiple sources of biomass can be used • Circular economy approach Image source: https://www.newfoodmagazine.com/news/134711/unilever-container-factory/ Aspirational Vision 2030 – 80% renewable fuels
- 21. 21 Australian Meat Processor Corporation Trade Waste Ponds • ‘Scuba Steve’ • A marine robot suitable for pond missions • Sample taking • Establishment of solids build up • Possible link to Stage 2 robotic targeted desludging Image source: https://www.sydney.edu.au/news-opinion/news/2019/03/14/prestigious-title-awarded-for-marine- robotics.html Image source: Unknown Aspirational Vision 2030 – Easier and Safer pond Mgt
- 22. 22 Australian Meat Processor Corporation Services Monitoring • Mapping of input and discharge services/points • Instrumentation support (wired and IoT) • Data platforms and analysis • Driving improvements and innovation initiatives Aspirational Vision 2030 – 24/7 monitoring Video source: https://www.youtube.com/watch?v=r8nWCJRI1AI&t=6s
- 23. 23 Australian Meat Processor Corporation Program Three Amanda Carter & Jemma Harper • Exo-skeletons • Bandsaw safety • Knife sharpening • Immersive reality • Innovation Managers People & Culture
- 24. 24 Australian Meat Processor Corporation People & Culture Overview • Meat processing is a Physically demanding job • Most common injuries in Meat Processing: • Manual Handling (58%) • Lacerations (29%) • Innovation leadership is a key enabler for the future 50% 7% 29% 3% 3% 8% Injury Type frequency (study 2018) Traumatic joint ligament and muscle/ tendon injury Musculoskeletal and connective tissue diseases Wounds, lacerations, amputations and internal Fractures Burns Other
- 25. 25 Australian Meat Processor Corporation Exo-Skeletons • History • Applications in other industries • Potential Applications of the Red Meat Industry • Research program of works • On-site evaluations with units from different providers Aspirational Vision 2030 – No muscoskeletal injuries Image source: https://eksobionics.com/
- 26. 26 Australian Meat Processor Corporation Bandsaw Safety (+++) • History • Application and uptake of the Red Meat Industry • Guardian 900 bandsaw • Project opportunity for Red Meat Processors Aspirational Vision 2030 – No bandsaw injuries Video source: https://www.youtube.com/watch?v=O-M_vOYy1rk&t=4s
- 27. 27 Australian Meat Processor Corporation Knife Sharpening • Knife sharpening is an important tool of the trade • Knife Sharpening App - AngleMe© • Will be available on the App store in the near future. Aspirational Vision 2030 – ‘Equalised’ knife skills
- 28. 28 Australian Meat Processor Corporation Immersive Reality • What is immersive reality for training? • How can it be used in the red meat processing sector? • Recruitment • Training • Career path progression Aspirational Vision 2030 – Ques of people line up for vacancies Video source: https://designtechco.com.au/
- 29. 29 Australian Meat Processor Corporation Processor Innovation Managers • 24 Innovation Managers • Across various components of the supply chain • Entire internal supply chain • Culture and people • Value-adding • Productivity • Sustainability • Delivering 79 projects across the country Adam Muir – MC Herds Aspirational Vision 2030 – Empowering Innov. Leadership
- 30. 30 Australian Meat Processor Corporation Program Four Matthew O’Bryan • Remote Verification • Tele-Vet • Traceability (slaughter, boning and steak) • Animal Welfare – Receivals and Lairage Technical Market Access & Markets
- 31. 31 Australian Meat Processor Corporation Remote verification • Issue: Availability of on-site verification • Effect: Increased regulatory cost, • Proposed Solution: Remote verification • Future: Training, maintenance, audits Image sources: https://elixar.com
- 32. 32 Australian Meat Processor Corporation Tele-Vet • Issue: Unplanned On-plant Vet absences • Effect: Delay to processing • Proposed Solution: Remote Ante-Mortem • Future: feedlot, transport, farm. Image sources: https://realwear.com/products/hmt-1/ https://gomohealth.com/2020/telehealth-top-5-the-telehealth-statistics-you-needtoknow https://www.beefcentral.com/production/ceres-ag-adopts-innovative-pasture-based-feedlot-model/ Aspirational Vision 2030 – Best industry AH&W outcomes
- 33. 33 Australian Meat Processor Corporation Traceability • Increase part traceability though: • Slaughter • Boning • Retail • Approaches: • Product surface printing (edible inks) • ‘QR’ codes • Cloud based software and ledgers Image source: https://www.seriouseats.com/2015/05/knife-skills-how-to- cut-a-whole-strip-into-steaks-beef.html Image source: https://seasonandthyme.com/meatballs-baked-in-egg-carton/ Aspirational Vision 2030 – Cost effective traceability
- 34. 34 Australian Meat Processor Corporation Animal Welfare • Innovation foci: • Receivals & Lairage automation • Advantages: • Increased workplace safety • Improved animal welfare • Improved yield through optimal triage • Overall productivity gains • Improved product quality Image sources: https://proway.com.au https://www.woolwise.com Aspirational Vision 2030 – Contactless lairage process
- 35. 35 Australian Meat Processor Corporation Program Five David Dwyer • New product developments (NPD) • AMPC’ NPD Academy Product & Process Integrity
- 36. 36 Australian Meat Processor Corporation Success or Failure Video source: https://www.youtube.com/watch?v=F4o2L9f2e54
- 37. 37 Australian Meat Processor Corporation New Product Development Supporting processors and value adders with NPD Private Formulation support Understanding niche market opportunities Identifying best on-site processing equipment Identifying when (and how) to Toll manufacture Moving Processors out of the box of Sameness Aspirational Vision 2030 – Increased $/kg profit
- 38. 38 Australian Meat Processor Corporation NPD Academy • Confidential advisory & support service your NPD manager • The program focusses on: • fundamentals of Novel NPD • idea generation • small batch feasibility analysis • small commercial product runs for market evaluation Aspirational Vision 2030 – Increased NPD innovation
- 39. 39 Australian Meat Processor Corporation NPD Academy Program: • R&D NPD tools of the trade • 5 x Sponsored R&D one on ones • 3 x conference education trips per year (events Local and overseas) • Limitless information on new development projects • Access to local and overseas machine manufacturers • 3 x two-day sessions at a state-of-the-art innovation hub, developing new product session.
- 40. 40 Modern Manufacturing - Q & A
Editor's Notes
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- What is Industry 4.0? The Google definition: The Fourth Industrial Revolution is the ongoing automation of traditional manufacturing and industrial practices, using modern smart technology. Well what does that mean? We are all still getting our head around what Industry 4.0 is and more importantly how we capture the benefits utilising industry 4.0 for the Red Meat Industry. To start simply I will show you soon some examples of IoT sensors and their simple application for equipment monitoring and services measurement. But we are going much further as we have projects in Artificial Intelligence & Machine Learning, digital twins and additive manufacturing or 3D printing that will be mentioned throughout our presentation today.
- The industry problem is ensuring optimized utilization of processing equipment or assets. Typically processing plants either over or under maintain equipment so, either spending too much opex on maintenance or causing significant processing and revenue loss with breakdowns. Vibration analysis of equipment is not new but this new approach utilising wireless vibration sensors provide a system that measures and transmits data to ensure accurate diagnosis can be performed on your machinery for predictive maintenance purposes. The system identifies faults based on set limits which, if breached, alerts users via email or text that there is an issue. These devices are perfect in dangerous and difficult to reach locations and not only reduce downtime and operational costs, but also increasing efficiency and extend your machinery life. AMPC aspiration is for all Red Meat Processing plants to have all critical equipment with remote monitoring. If you want to know any more about IoT devices please come and see the AMPC team. I will now hand over to Matt Deegan
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- The industry problem here is for waste water treatment ponds having unknown volume loss due to build up of crust on the top of the pond (as per image on the slide) and sludge solids build up at the base of the pond. To access these ponds to attempt to take samples is difficult at best and considerably unsafe. I'm sure Adam Sandler would approve of our Scuba Steve project to develop a marine robot that can be placed into the pond to take samples of waste water at various heights within the pond as well as to establish the depth of solids build up. This will give a much better understanding of upstream waste water treatment system performance as well as pond life expectancy and clean out / dredging requirements. It is anticipated that stage 2 will be further development for a solution for robotic dredging unit specifically for red meat waste water treatment ponds. The aspiration of this project is to provide industry with a solution that allows waste water pond inspection to enable improved environmental performance and safer for our people.
- Processing plants struggle to attract and retain skilled staff in particular maintenance staff and by default equipment monitoring (and performance) has significantly suffered. Current practice for steam trap monitoring has a maintenance person “listening” to the steam traps with using a screw driver to their ear in a stethoscope method. This project is adapting and evaluating continuous monitoring using wireless technology for steam traps to ensure the maximum level of condensate is recovered, and minimum amount of steam is lost, therefore saving energy and money. AMPC aspiration is for all services to be remotely monitored 24/7 allowing improved asset and resource management. If you want to know any more about IoT devices please come and see the AMPC team. I will now hand over to Amanda Carter
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Top line positive Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement
- Investigate opportunities for use Steps: Study to review ergonomic demands on tasks across industry Trial exso-skeltons and potential use area Access benefits and area of further improvement