Column IJsbrand Velzeboer: Autocalypse on the production floor

Automation brings many benefits to a company. Processes become more efficient, the workload is reduced, and you save costs by needing fewer employees. But there is a catch...

Do you know John? He was a veteran. A bit of a grump, who not too long ago, after 35 years of loyal service, walked out the door for the last time. He knew the company inside and out; every switch, every sensor, every emergency stop. He knew how the pipes were laid. Starting the production process manually was second nature to him. Breakdowns were quickly fixed, often before anyone even noticed. But an automation overhaul and a robot made him redundant. There was a farewell reception in the canteen, with coffee, cake, and a goodbye speech from the director, and off John went. Back home, he put the traditional farewell gift, a set of silver-plated teaspoons, in the drawer. He got up, his hands comfortably in the pockets of his jeans, and looked out of the window, enjoying the newfound calm in his life.

Disastrous events

Does automation bring the same calm to the workplace? I wonder. We lull ourselves into a false sense of security, trusting that computer-controlled processes will always go smoothly. Everywhere I look, I see the apocalyptic consequences of something going wrong with the computer. For example, a Microsoft update error in July of this year pretty much of shut down the entire world. It was a massive wake-up call for our computer-dependent generation.

In the food industry, computer-related disasters occur more often than we realize. Many companies are too embarrassed to air their dirty ‘computer laundry.’ In the past, you had highwaymen; today, we talk about cybercriminals. Ransomware and DDoS attacks cause significant damage in companies almost daily. And I haven't even discussed the vulnerability of satellite connections, cloud services, and the undersea data cables scattered across the ocean floor.

Not an easy fix

Automation is wonderful, until something breaks down. The company's sales and procurement systems come to a halt, the production process can't find the recipes, raw materials go missing, and the entire staff is sitting in the canteen playing cards. Process disruptions lead to costly product losses. Registrations, verifications, and product safety suddenly become unreliable. Where are the paper registration forms? Who knows how to start the line manually? Where is John… help! The new generation thinks everything can be fixed quickly. They know more but are less capable. "A backup with two legs is priceless." And by that, I don’t mean an extra hard drive or cloud storage. I’m talking about that person with all the knowledge, the one who not long ago left the company without much thought. While he’s sitting comfortably at home, the chaos at his former employer’s company has only increased.

Tips & tricks

What measures can you take ‘just in case’?

• Set up a shadow control system with an autonomous computer running on batteries to capture the most essential data and runs in the background. The auto industry has been using this for many years. When there’s a severe malfunction in a car’s electronics, a ‘limp-home module’ kicks in, allowing the driver to still get home with some delay.
• Simulate a breakdown by turning off the main switch for 15 minutes. You’ll gain valuable insights from this. The company’s insurer will likely appreciate these exercises if they’re well-evaluated.
• Document all the knowledge stored in people’s heads. It’s challenging to get stubborn employees who can’t or won’t explain things to share what they know.
• Ensure that operators and employees have a deep understanding of all production processes. Don’t let them just push red and green buttons or use a keyboard.

Every company holds valuable expertise that ensures food safety. It’s essential to have technological and technical knowledge on the production floor that’s shared across all employees. They support each other in tough situations. Any training plan should include this. It makes a company less vulnerable to potential disasters.

IJsbrand Velzeboer
Food Technologist

www.scientanova.com