Customized FMCG Production via Side Stream Segmentation

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Solution Overview

Problem

Current manufacturing processes for fast-moving consumer goods (FMCGs) are inefficient in producing customized products at high speeds due to manual steps, high operational costs, and limited capabilities of customization equipment, resulting in low customization rates and significant logistical challenges.

Innovation Solution

A process that allows for the production of customized FMCGs in parallel with standard products, using an interim storage device to temporarily store customized products and re-feed them into the main production stream, enabling efficient packaging and supply chain management, and incorporating advanced systems for design data acquisition and material metering to match customizer requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If customization processes (such as inkjet printing) are used to produce customized FMCGs, then product customization capability is improved, but production speed is reduced and operational costs increase

Engineering Contradiction:

Improvecustomization capabilityVSAvoidproduction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The production system is divided into a main stream production process operating at high speed and a side stream production process handling customization at lower speed. Customized products are produced in the side stream and then re-fed into the main stream, allowing the main production line to maintain full speed while customization needs are met.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An interim storage device acts as an intermediary between the side stream customization process and the main stream production process. This buffer storage allows customized products to be temporarily held and then re-fed into the main stream at appropriate times, decoupling the speed requirements of customization from the main production line.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If dedicated manufacturing systems operate at high speed, then production efficiency is improved, but flexibility to produce customized products is reduced

Engineering Contradiction:

Improveproduction efficiencyVSAvoidproduct customization flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The main stream production process is designed to handle both standard and customized products through a universal re-feeding mechanism. The interim storage device and re-feeding system allow the high-speed main line to universally process different product types without requiring dedicated configuration changes for each customization.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The production system dynamically adjusts by routing standard products through the high-speed main stream while directing customized products through the side stream with interim storage. This dynamic routing allows the system to adapt its processing path based on product requirements while maintaining overall high efficiency.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If manual steps are involved in customization processes, then product personalization is improved, but operational costs and time consumption increase

Engineering Contradiction:

Improveproduct personalizationVSAvoidtime consumption

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The side stream production process is designed to be as automated as possible, with computer-controlled customization equipment applying personalization features automatically. The system retrieves design data, configures customization parameters, and executes the personalization process without manual intervention, reducing both time and cost while maintaining personalization quality.

Inventive Principle:

Principle #25Self-service

4Manufacturing precision

If customization equipment runs at lower speed, then customization quality is improved, but overall production throughput is reduced

Engineering Contradiction:

Improvecustomization qualityVSAvoidproduction throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The production system segments customization operations into a separate side stream process that operates independently at optimized speeds for quality. The main stream continues at full speed handling standard products, so the lower speed of customization equipment does not bottleneck overall production throughput.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interim storage device mediates between the lower-speed customization process and the high-speed main production line. Customized products are produced at lower speed with high quality, stored temporarily, and then re-fed into the main stream, allowing quality-focused customization to coexist with high-throughput production.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11219557B2Customized fast moving consumer goods production system

Publication Date: 2022.01.11 SCAIFE MARTIN

AI summary

A manufacturing method for customized fast moving consumer goods (FMCG) comprising the production of the customized goods in a main production process stream or a side stream. The method further comprises temporarily storing the customized goods in a side stream process and subsequently re-inserting said goods into the main production process stream. The customized goods may be finally packaged in a dedicated pack or in a pack that also contains non-customized goods. The method is suitable for, but not limited to, articles such as diapers, absorbent products, tissues and other hygienic products.