P.PSH.1303 - LEAP IV - Middle System Performance Upgrades and Value Engineering

Summary

This project will utilise advancements in 3D vision analysis combined with artificial intelligence techniques to target and significantly improve high value areas of benefit in the LEAP IV module such as Eye of loin Flap cut path identification and specification tolerance. Currently the system utilises a basic RGB analysis of the loin cut surface to calculate the tangent edge. Flap cutting has a benefit of $0.85 to $0.99 to the $7.70/head attributable to yield alone for the Scott LEAP sweep of modules. As an outcome of this project there will be a number of upgrades that can be rolled out as retrofitable packages to any existing machines as well as incorporated as standard into new machines.

Objectives

The major objectives of this project are:
1. Design and build retrofittable packages for the critical upgrades identified above for existing and future LEAP systems.
2. Demonstrate the upgrades to industry through installation of an existing LEAP system. The final report will detail upgrade packages that have been developed.

Key findings

The offline results how there was a significant improvement in accuracy for both the rack analysis, loin analysis and product positioning. The accuracy results achieved offline represent the potential for a significant benefit to the customer when they are able to be integrated into a production system. Given that the majority of the benefits of the LEAP IV Middle system are due to accuracy, these improvements will provide meaningful benefits to the customers once successfully implemented on site.

Due to software communications issues on site, the upgrade was unable to be tested on product at a processor’s site. However, Scott is currently building a LEAP IV Middle system and the upgrade kit will be thoroughly tested during factory commissioning before it is deployed to an Australasian site. Once tested on site to ensure reliability the upgrade kit will be able to be easily retrofitted to existing LEAP IV installations, due to the lack of hardware changes.

Benefits to industry

The offline tests on the upgraded rack and loin flap analysis indicates an improvement by a factor of 2 – 3. There are additional benefits due to the reduced rework and ability to more accurately specify the cut positions. Once the factory and on-site commissioning of the upgrade kit are completed with the upcoming LEAP IV Middle system the Middle Upgrade kit will be able to provide significant benefits to both new LEAP IV systems, as well as existing systems as a retrofittable upgrade.

MLA action

MLA is currently looking at collaborating with Scott Automation & Robotics again for future research projects in the processing productivity area.

Future research

Scott is currently continuing to develop the communications software to allow the upgraded analysis to robustly run in production. An upcoming LEAP IV Middle system is currently being built in the Scott Dunedin factory and once factory commissioning begins in August 2023 the software team will be able to thoroughly test the robustness of the upgraded software. Once this step is complete the upgrade kit will be available to upgrade existing LEAP IV installations and as standard for new LEAP IV systems in future.