A Framework for 3D Plant Simulation of Meal-Kit-Packaging Robot Automation System

A data-driven 3D simulation for the robotic automation of the most labor-intensive packaging process in meal kit production was developed using Tecnomatix plant simulation software. The workflow and environments of the existing manual process were analyzed. An existing production site was scanned using a 3D Lidar scanner to create 3D models and design the initial assembly layout. Two types of 3D simulation models, implemented with a single or double delta robot, were designed to determine the optimal robot-automated packaging process. Key performance indicators for simulation models of a manual and two robot automation systems were analyzed. The throughputs of the manual, single delta robot and double delta robot models were 2112, 1510, and 2568 ea/h, respectively. The single robot system achieved only 68.3% of the throughput of the manual process, which is attributed to a cycle time of 2.36 s for picking and placing all components. On the other hand, the cycle time of the double robot system was 1.66 times faster, and the throughput was 1.7 times greater compared to the single robot system. The developed 3D simulation model for the meal kit packaging system demonstrates the potential of robotic automation in addressing the labor shortage issue as well as improving production efficiency.