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INDUSTRY 4.0A VIEW FROM R&D IN FMCG
JON HAGUE
VICE PRESIDENT OPERATIONS AND OPEN INNOVATION
UNILEVER GLOBAL R&D
TeaUnit Dose
Aerosol & sprays Powders Water filters
Liquids & pastesCold Supply
Chain
Bars & blocks
WHAT WE MAKE
UNILEVER IN THE NORTH WEST– A DIGITAL ECOSYSTEM
Advanced Manufacturing Centre
Materials Innovation Factory
North-West Science Grid
€30m investment€78m investmentStrategic relationships
*BCG Report Speed to Win April 2012
Best in class FMCG Companies introduceInnovations seven months faster
Resulting in 60% higher sales in first year
BestAverage Average Best
7 Months
22 Months
15 Months
1% of sales
1.6 % of sales
60%
THE VALUE OF SPEED
• Produces 24 x 800g batches a day in 4 parallel formulation modules.
• Raw material format handling and dosing robustness.
• Capable of end-point prediction and correction.
• Excellent process control enables better scale up predictions (to AMC).
FFSTANDARDISE – AUTOMATE – DIGITISE IN FORMULATION
1 Litre FULLFormulationsPer person perday
Manual, non – standard 2 -3
Manual, standardised, 5 - 7
Automated, 25
In silico1000’s
OUR DIGITAL FORMULATION JOURNEY
Newmaterials
SimpleMixtures
ProductFormats
FullFormulae
Manufacture
Launch
Computer AidedFormulation
Optimiser Engines
Virtual EngineeringProcessing
Virtual EngineeringPackaging
Factory LineOptimization
Manufacture To demand
WE ARE THINKING END TO END
0
20
40
60
80
100
0 20 40 60 80 100 %C12E6
T (°C
)
Manual3 months
HPC Mesoscale30 Minutes
LEADING THE WAY IN MESOSCALE MODELLING
Process & Equipment
Design
Product Structure
Complex Fluid
Properties
Fluid flow
IT’S A BIG CHALLENGETOTAL PROPERTY AND IN USE PERFORMANCE
THE SCIENCE – MULTICOMPONENT LIQUIDS ARE MASSIVELY COMPLEX TO SIMULATE, LENGTH SCALES AND PROCESS CONDITIONS MATTER
SENSORING UP OUR FACTORIES – MASSIVE INSTALLED CAPITAL BASE WITH A LOW RENEWAL RATE
TURNING PRIMARY DATA TO REAL TIME INFORMATION AND ACTIONABLE MODELS
SOME OF OUR CHALLENGES