Exp. 7 - Simulating and improving food packaging with the objective of waste reduction
The problem currently faced by TreValli is the issue related to an unforeseen stop on the production lines, for instance due to a sudden breakdown of one conveyor or to a machine along the lines that goes out of service. In such case, for some dairy products, there is a 5 minute timeframe to solve the problem and restart the line.
In case they are unable to solve the issue in time, the whole line has to be stopped and in the worst case everything that is currently inside the filling machine has to be disposed.
To ease the possibility of covering the majority of the possible error cases the team has decided to execute a simulation for each error case simultaneously.
The main goal of the experiment is to help the end user to identify potentials to extend the 5 minute timeframe as much as possible to avoid wasting the material.
To achieve that goal the realtime simulation software industrialPhysics is utilized to simulate the error cases simultaneously and independently of each other.
From the technical point of view the used simulation software is extended in a way to be used as a service, which can be used for future projects without the need to buy expensive hardware.
Furthermore for the vendor of the production line there is the potential to find new ways to optimize the throughput of their line in case a problem occurs.
The main outcome of the experiment for Machineering is the “servitization” of the main product industrialPhysics. By making it possible to “decouple” the simulation itself from the visualization it is assumed that it might be able to reduce the system requirements, resulting in decreased hardware costs. Thanks to the advancements brought in CloudiFacturing it will be possible to maximise the scalability aspect of IndustrialPhysics as new customers won’t need no more to invest in really sophisticated hardware as not needed for “visualising” the simulation. Therefore, Machineering will be able to address new customers in a more efficient way. In Europe there is plenty of potential customers in the dairy product market (e.g. Aria foods, CSK, UKR, Euroserum, Fage, etc.) that are using very similar machineries to the one in use by Tre Valli, meaning a tangible potential to introduce and implement the industrialPhysics solution and unleash the scalability potential of the company. The expected economic impacts of Machineering in this project are: one new product, one new employee and improvement of customer satisfaction after one year of the experiment; three to five new products, three additional employees and twenty new partners in different countries after five years of the experiment. By lowering the acquisition costs for the simulation software (cutting hardware expenses) it is also expected that additional licenses will be sold.