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Unilever Engineers League

Avatar for MD NAYEEM HOSSAIN MD NAYEEM HOSSAIN
March 13, 2024
11

Unilever Engineers League

Technical Case Study: Pallet buffer change for new AMR robot pallet delivery
Factory visit: Real work experience inside the factory
Solution: Designed an automatic pallet feeding station
Programing and Simulation Software: Fatory I/O

Avatar for MD NAYEEM HOSSAIN

MD NAYEEM HOSSAIN

March 13, 2024
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Transcript

  1. Hossain Md Nayeem Arifuzzaman Arif Muhammad Muhaiminul Islam TEAM INTRODUCTION

    Electrical Engineering Biochemical Engineering Food Engineering
  2. OUTLINE ANALYSIS OF UNILEVER’S ENGINEERING PRACTICE EXISTING OPERATION ANALYSIS PROPOSED

    SOLUTION SIMULATION BENEFITS OF THE SOLUTION COST ANALYSIS​
  3. Engineering Practice: Company Vision: Sustainable, Digital, Biological Sustainable Engineering: Reducing

    energy consumption, minimizing waste, and using renewable energy sources Digital Engineering: Artificial intelligence, Machine learning, IOT Packaging Engineering: Use less plastic and more recyclable. Safety Engineering: Risk assessments, safety training Innovation: The road to 4.0
  4. Current Operation Analysis 1 2 3 4 Loading Pallet from

    Stock Manually operating Fork lift carrying Pallet from Stock to Buffer Area Waiting for the dispenser to be empty Incoming of Pallets and dropping to Buffer Zone 5 Picking the Pallets from Buffer Zone Manually feeding the Pallest to the Dispenser according to demand 6
  5. Shortcomings of Current Operation Shortcomings Manual Operation Labor cost Less

    Efficient More Operation time Safety of Workers Risk Less Pallet life time in production line due to hard intervention Cost inefficient in long term
  6. Brainstorming: Robotic arm? -3 axis movement, space consuming -Price of

    15 x 12=180 kg weight handling capable arm is expensive! AGV forklift with feeding unit? -High purchase & maintenance cost So, we looked for something sustainable, feasible, compatible with existing infrastructure, IOT compatible..
  7. Introducing Our Solution: Roller conveyor that houses pallet stack and

    delivers back when necessary. Integration with PLC makes it Intelligent. Intelligent Buffer conveyor To transfer the pallet stack to the intelligent conveyor. Curved Conveyor Keeps the operation area enclosed to avoid accidents. Safety Fence Turns 90 degrees to transfer the pallet stack to the intelligent buffer conveyor Turntable Conveyor top Receiving end is compatible with both manual and AMR operations AMR Conveyor Interface Compatible with the AMR that’s being used in other Unilever factories AMR Industrial automation Dispensing Unit The retroreflective sensor senses the presence of pallets at the necessary points. Sensors
  8. Floor Plan Applicability of the Solution: • Fits Perfectly •

    Clean Operation area • Accessible receiving end Buffer 1 Buffer 2 Receiving End 2200mm 2000mm 1200mm 2400mm
  9. Operation Flow Receiving of pallet Our receiving terminal is compatible

    with both Forklift and AMR operation Logical Analysis Depending on the presence of pallet in the dispenser, our PLC system decides whether to feed directly or to put on the buffer Conveyor Intelligent Buffer If there’s already pallet in the pallet Dispenser, the pallets are sent to the Buffer conveyors Feeding Dispenser As soon as the Dispenser is empty, pallets will be fed either from the receiving terminal or from the intelligent buffer depending on the availability 1st 2nd Internal operation
  10. Simulation Of the Proposed Solution Case 1: Direct Feeding Case

    2: Continuous Feeding Case 3: Placing stack to buffer Conveyor Case 4: Feeding from the buffer conveyor
  11. Basic Procurement Cost Pallet Receive Zone AMR Conveyor Interface Possible

    Supplier: Computech Dimension: 1200x1200x900 mm Load Capacity: 1500 Kg 1200€ Turntable YUPACK Turntable Possible Supplier: Gravity Conveyor Dimension: 1850x1850x900mm Load Capacity: 1500 Kg 4500€ Curved Roller Conveyor Curved conveyor Possible Supplier: Gravity Conveyor Dimension: 1500x1000x900mm Load Capacity: 1000 Kg 500€ Roller Conveyor Roller Conveyor Possible Supplier: Gravity Conveyor Dimension: 1200x1000x900mm Load Capacity: 1000 Kg 1500€ Sensors Industrial Sensors Possible Supplier: Gravity Conveyor Dimension: 30x30x20mm Not Relevant 300€
  12. Benefits The simple yet effective solution is least complex, and

    do not require extensive training to control and manipulate Simplicity All the proposed equipment are widely available in a competitive price, installation doesn’t require complicated Feasibility Less procurement, installation, operating, depreciation cost than current procedure and possible alternative solutions like Robotic Arm Cost efficiency PLC based control allows integration with existing infrastructure, and future upgradation to IOT system as part of the Industry 4.0 Roadmap. Compatibility No human intervention and unguarded mobile elements involved, leading to safer working environment Safety
  13. Cost analysis Present operation Shift time t = 8 hrs

    = 480 min No of labor L = 1 Cost per shift, C= 1 x 8.33 x 8 = 133.28 Euro Time for feeding a stack T = 20% of shift time Cost of operation per shift Cp = 20% of 133.28 = 26.3 Euro Proposed operation Time for feeding one stack T = 2.5 min (max). Total no of pallet stack N= 480/2.5 = 190 Stack Saving per shift = 26 Euro Saving per Month = 26 x 24 = 624 Euro
  14. Investment Payback Period • Total investment: Apr. 8000€ • Savings

    per year: Apr. 7488€ • Payback period= 8000€ 7488€ = 1 𝑦𝑒𝑎𝑟 1 𝑚𝑜𝑛𝑡ℎ. • Considering the depreciation cost and overall unit productivity output proxy values the number would be significantly lower.