The year is 2024 A.D. Finland is entirely occupied by those that drive automation. Well, not entirely. One small facility of indomitable machines still holds out against the invaders. And life is not easy for the brave engineers who garrison the cities of Kuopio, Tammerfors and Helsinki.
Finally a true hero named Siemens brought automation to these lands. But now enough for the Asterix references. 

The reasons for automation in this case were mostly old, unreliable and difficult-to-repair machinery combined with the remote location of the facility. But we will come to the benefits later in this text. For now, let us take the above example to illustrate a path to automation. The facility in Juuka is specialized in the production of stocks, sauces, and broths, utilizing predominantly aged machinery that frequently encounters breakdowns. The challenge arises from extended downtime periods while awaiting a technician to arrive from a considerable distance. In a proactive effort to mitigate these challenges, the production process has undergone significant automation involving a systematic six-step approach.     
The process kicks off with the formation of a team dedicated to co-creation. Through collaborative workshops, the team delves into identifying both the problems and the opportunities with its challenges at hand. The next step involves evaluating and developing a solution that aligns with the defined goals and opportunities. This cohesive team continues to work seamlessly together. Once these initial four phases (get together, identify the problem, create a solution, proceed as team) are completed, the solution is implemented. As concurrent efforts are made to guarantee the planned objectives are met. It’s important to note in the last step that (digital) transformation is an ongoing journey with no defined endpoint.           
This process sounds very simple. But when you are directly involved, it is much more complicated. Especially how to get started in the first place. The first step is to document the status quo. In this case, the entire factory was measured with 3D lasers and baseline data was created for simulation and the basis of the layout, simulation and images was created. A digital twin was then created from this data. The topic of digital twin is dealt with in depth in Oliver Lardon’s blog. This was used to simulate the material flow to identify and eliminate bottlenecks. Modifications and extensions were also tested in this way.             
The selected measures are now being implemented and the technology behind them is being realised in parallel to bring them together and make them visible to users. After a test phase, the system will go live. As highlighted earlier, the journey does not conclude with the go-live stage. Continuous improvement begins. Data needs to be collected, which is easy thanks to the sensors connected to the automation. This data can also be visualised in raw form to increase transparency. But the data is much more valuable when it is analysed. It can be used for monitoring, optimisation or predictive maintenance. By monitoring KPIs, trends can be identified and optimisation can be driven forward.

In the end, these outcomes translate into several advantages. Notably, cost savings are realized through the reduction of waste and rework in raw materials. There are also potential savings in energy, water, and cleaning costs. Beyond cost efficiencies, time is conserved through the optimization of processes, ensuring punctual delivery to the costumers. And what could be cooler than economy meeting ecology?                      
The same principles extend to the broader scope of automation at a macro level. Additional advantages encompass increased efficiency, maintaining consistent quality for superior control, and elevated food safety standards. Furthermore, automation often leads to cost reductions, improved traceability, and enhanced monitoring and control over the process. However, it’s important to acknowledge potential challenges, including substantial initial costs, the necessity for a skilled workforce, reduced flexibility, and dependence on technology. 
It can be concluded that automation is a transformative force in food production. While there are risks, strategic integration will ensure a resilient and future-ready industry. By managing the challenges wisely, manufacturers can unlock the full potential of automation for sustainable success.

Remo Lukas König

Image source: 
Nestlé Juuka: From outdated to trendsetting – References Food & Beverage – Siemens Global Website 
https://www.siemens.com/global/en/industries/food-beverage/references/nestle.html