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December 17, 2020 11:30 pm

AI-Enabled Cheetos Offer Promise of the Perfect Puff

Microsoft says in a blog post that PepsiCo is using their Project Bonsai "machine teaching" service to "help ensure its Cheetos cheese-puff snacks all have the same texture, crunch and shape," reports The Wall Street Journal. From the blog post: PepsiCo built a computer vision system that continually monitors Cheeto attributes. Data about qualities such as density and length are fed to the Project Bonsai solution, which makes adjustments to bring the product within spec. This approach reduces the time it takes to correct inconsistencies and allows operators to focus on parts of the line that require human expertise. PepsiCo is preparing to use the solution in a production plant and exploring how to use the solution with other products, including the tortilla chip manufacturing process. An out-of-spec product can't be sold, which leads to wasted resources, time, and money. Greater consistency helps PepsiCo maintain high quality products while maximizing throughput. To make an ideal Cheeto, the solution needed examples of what wasn't ideal -- and needed to know what to do in those cases. The extruder line is self-contained and well-suited for developing and testing an autonomous system solution. Operators had been running it manually, which gave developers the opportunity to build the solution from scratch, instead of on top of other software. The AI solution has a recommendation mode and a closed loop control mode. In both modes, a computer vision system continuously measures the quality of the Cheetos. In recommendation mode, the AI will alert an operator if the product drifts out of spec, displaying on an instrument panel the attributes that are not ideal as well as a recommendation to correct it. The operator can push a button to make any or all recommended adjustments. In control mode, the only difference is that the AI solution skips the recommendation step and adjusts the extruder line specifications independently. The company expects that running this intelligent control system will return product to acceptable attributes faster. In the current extruder line, operators measure product attributes manually at defined intervals. If the Cheetos are out of spec, the operator makes adjustments based on guidelines or experience to return the product to acceptable quality. The problem: Infrequent sampling meant that the line could be producing out-of-spec Cheetos for a longer period of time without anyone realizing. The Project Bonsai solution will monitor the product almost continuously, using sensors to oversee characteristics such as length and bulk density. That way, it knows as soon as the product strays outside a defined range.

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