The food manufacturing industry continues to face a serious labor shortage due to Japan’s declining birthrate and aging population. As it becomes increasingly difficult to secure workers on the production floor, the introduction of automated equipment is attracting attention. This article clearly explains the specific benefits of automation for those in charge of equipment.
1. The Current State of Worsening Labor Shortages
The effective job-to-applicant ratio in the food manufacturing industry remains high at approximately 2.5, with multiple companies competing for each job seeker. Furthermore, due to the demanding working conditions such as night shifts and standing work, there is an additional challenge of low retention rates even when workers are hired.
Main Challenges Caused by Labor Shortages
2. Five Benefits of Automation
① Optimized Staffing
Routine tasks can be delegated to machines, allowing people to focus on inspection and management tasks.
② Improved Productivity
24-hour operation becomes possible, eliminating production stoppages due to breaks and fatigue.
③ Stabilized Quality
Reduces human error and maintains consistent quality at all times.
④ Improved Working Environment
Frees workers from heavy labor and hazardous tasks, reducing turnover rates.
⑤ Cost Reduction
Long-term cost benefits arise from reduced labor costs and improved production efficiency.
3. Automation Equipment Easy to Introduce in Food Factories
With stricter hygiene management required by HACCP mandates, the introduction of automated equipment also contributes to maintaining hygiene standards.
| Equipment Type | Main Uses | Introduction Difficulty |
|---|---|---|
| Automatic weighing system | Accurate weighing and feeding of raw materials | ★☆☆ |
| Packaging/filling machines | Product packaging and bagging operations | ★☆☆ |
| Transport robots | Transporting products and raw materials | ★★☆ |
| Inspection systems | Detection of foreign matter and defective products | ★★☆ |
| Collaborative robots | Picking and boxing operations | ★★★ |
💡 Tips for Introduction
Rather than aiming for large-scale automation all at once, we recommend starting with simple tasks or processes with serious labor shortages and introducing automation gradually. Starting with equipment that can work alongside people, such as collaborative robots, reduces employee resistance and makes introduction easier. Automated equipment also reduces the chance of human contact, making it effective for HACCP’s “cross-contamination prevention” standard.
4. Precautions When Introducing Automation
Automation has many benefits, but the following points require attention when introducing it.
Planning the Initial Investment
Equipment introduction requires significant costs. Consider utilizing subsidy programs and leasing or rental options. Programs such as the “Monozukuri Subsidy” for small and medium-sized enterprises may be available.
Employee Training
Employees who handle automated equipment need training on basic operation and troubleshooting. Be sure to also check the manufacturer’s support system.
Maintenance System
Regular inspections and parts replacement are necessary. To minimize downtime, it is important to thoroughly review the contents of the maintenance contract.
5. Summary
Automation in food factories not only compensates for labor shortages, but also brings multi-faceted benefits including improved productivity, stabilized quality, and improved working environments. Furthermore, as a response to HACCP, which became fully mandatory in June 2021, improved hygiene management through automation is an important element. Rather than aiming for full automation, why not consider gradual introduction tailored to your company’s challenges, from the perspective of “collaboration” between people and machines?
Automation is by no means “for reducing people.” It is an investment for assigning limited human resources to higher-value tasks and building a sustainable production system. We recommend first organizing the challenges on the production floor and starting with a small-scale introduction.
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