Boosting Productivity at Unilever Besan

This facility utilized multi-point conveyor inputs and outputs as well as multi-point to multi-point material distribution, resulting in complex and intersecting paths between key locations. There were no dedicated paths or directions. A traditional conveyor system would be nearly impossible with the existing setup, as it would need intersecting static conveyor lines, which would be costly, complex, and would create roadblocks in key areas.

Despite the tight space, forklifts, human workers, and AMRs were working in the same area on multiple operations at the same time, creating traffic jams and unsafe situations for workers. With three shifts and 24/7 operation at high outputs, labor costs were high. These high labor costs were exacerbated further by the fact that operators who could have been used in a skill-needed duty were spending time carrying materials between locations.

In some cases, unstretched materials needed to be carried on pallets, causing safety and stability concerns. Production, stretching, and truck loading were ali automated. However, the operator-dependent transfer of materials between operations was slowing things down, preventing a fully-automatic trackable operation flow. Different truck destinations matched with different material types based on the orders. However, this facility did not have full integration with the EOL output MES, truck schedule system or AMR fleet management system.

Additionally, there was a need for greater speed and efficiency overall, particularly during peak season. Pallet delivery needs doubled during peak season from 60 pallets per hour on average to approximately 120 pallets per hour at peak.