Navigating the Evolution of Manufacturing

When navigating the evolution of manufacturing, companies must embrace a multifaceted approach that combines automation, energy efficiency, and predictive maintenance strategies to be successful. Image courtesy of Regal Rexnord

How to meet business goals while adapting to a continually changing industry.

Regal Rexnord’s Joe Pahlow, Mechanical Conveyor Engineering Expert – Automation Solutions & David Goldman, Business Development Manager – Perceptiv Reliability Solutions

Efficiency and productivity are more critical than ever in the manufacturing industry. High consumer demand, combined with challenging economic conditions, have created the drive to push out as much product as possible while maintaining quality standards that keep customers happy. Figuring out how to address the challenges of scaling product throughput while saving time and cutting costs can be overwhelming. How can you ensure quality and efficiency while meeting business KPIs? Where do you begin?

How Automation is Revolutionizing Manufacturing Warehouses

Many manufacturing warehouses have started to implement automated processes to keep up with demand and reduce labor costs. Supply chain demands, coupled with workforce retention challenges, have led to trying to do more with a smaller labor force by adopting automated conveyors and introducing automation through technologies such as collaborative robots.

Packaging has also been continuously evolving, with the introduction of thinner container types, reduced cardboard, and litho-printed bags. These new packaging types create challenges for warehouses, as their existing conveyor lines may not be able to handle them without product damage or blockages due to how they slide or accumulate. Manufacturing facilities have been forced to re-evaluate their systems for these new products and packaging types. This could mean using automated programming and control systems for handling multiple types of products. Technologies like a robotic photo eye can tell the system to activate or turn off based on what type of product or packaging it sees. While these technologies may have higher upfront costs, the speed, reliability, and efficiency of these automation systems provides a return on investment that allows more savings over time and increased profits due to greater productivity and reduced downtime.

The Importance of Energy Efficiency and Sustainability

Energy efficiency and sustainability are also becoming increasingly important. As companies strive to reduce costs and improve their environmental footprint, the design and operation of their systems play a crucial role.

Sustainable choices are often a long-term financial win for manufacturers. Energy efficiency and cost reduction tend to go hand in hand. By integrating energy-efficient motors and modular sortation systems, companies can achieve significant cost savings while reducing their environmental impact. Modular systems allow for easy reconfiguration and expansion, which is important in dynamic environments where product lines and production volumes can change rapidly. This flexibility allows for easy adaptability to new market demands without the need for a complete system overhaul, saving both time and resources.

The reliability of these systems is crucial, as unplanned downtime can be costly and disruptive. There are also government incentives and rebates for energy-efficient equipment which can further offset the initial investment of implementing these technologies, making the transition to sustainable practices even more attractive.

Preventative Maintenance and Condition Monitoring Increases Uptime

Downtime can be extremely costly, leading to lost productivity and revenue.  Along with regular maintenance, preventative maintenance is essential to ensure smooth and efficient operation. The use of condition monitoring devices, such as sensors, is a game-changer. These devices can predict potential issues before they become major problems, allowing for timely and effective maintenance. For example, monitoring temperature and vibration can help in scheduling maintenance before a breakdown occurs. By detecting anomalies early, these sensors help in reducing unplanned downtime and extending the life of the assets.

There are also significant cost savings, along with inventory management benefits, that come with proactive maintenance strategies. Regular monitoring allows companies to better manage their inventory of spare parts, reducing the need for emergency replacements and minimizing storage costs. Additionally, the challenges of workforce skillsets in maintenance teams can be mitigated with the help of advanced technology. These tools provide real-time data and insights, enabling less experienced technicians to perform maintenance tasks more effectively.

Future-Proofing Your Strategies

When navigating the evolution of manufacturing, companies must embrace a multifaceted approach that combines automation, energy efficiency, and predictive maintenance strategies to be successful. By integrating advanced technologies and sustainable practices, manufacturers can meet the dual challenges of high consumer demand and economic constraints. Automation not only enhances efficiency and reduces labor costs but also ensures the smooth handling of new packaging types. Energy-efficient systems offer both financial and environmental benefits, while condition monitoring can prevent costly downtime and extend asset life. Together, these strategies create a resilient and adaptable manufacturing environment, positioning companies for long-term success and profitability.

About the Authors

Joe Pahlow is a Mechanical Conveyor Engineering Expert for Regal Rexnord Automation Solutions. Starting his career at Arrowhead Conveyor, Joe has been working with conveyors for over 30 years. He is passionate about finding the best solutions to solve unique customer problems and the exciting and challenging adventure of new products and configurations.

David Goldman is a Business Development Manager, Digital & Technology Solutions at Regal Rexnord. With a background in various industries such as oil and gas, construction, and condition monitoring solutions, David is intimately familiar with many application and equipment challenges. He is most excited and honored to have the opportunity to travel across the United States, partnering with facilities to reduce costs and improve the overall reliability at their plants.

Learn more at: https://www.perceptiv.com/