Navigating Automation: Building Success Through Reliable Partnerships

An automated process is most effective when all the supporting elements, such as material handling and personnel, are aligned to complement it. © Gorodenkoff – stock.adobe.com
By Joe Albert, Director of Equipment Sales for Signode
The relentless pursuit of efficiency is a driving force behind success in the fast-paced world of manufacturing. As an operation grows and evolves, investing in new equipment is an inherent part of the equation, which has led industry leaders across multiple verticals to turn toward automation. Because automation offers increased efficiency and the ability to fill in gaps caused by labor shortages, it is an ideal scalable solution for increasing market demands — when implemented correctly.
Automation is not a one-size-fits-all solution, and unanticipated obstacles — like your brand-new machine not having the desired effect once integrated into your production line — can arise along the journey. That’s where a reliable and experienced partner comes in handy. They are more than just equipment suppliers — they understand which machinery and packaging materials will most benefit your manufacturing line and discern how even a single alteration can resonate throughout the entire production flow.
The Realities and Nuances of Automation
The rising popularity of automation has led to a market teeming with incredible new advances, and it’s tempting to believe that investing in the latest machinery is the key to success. However, automation is only as successful as the entire operation it’s integrated into. Whether you’re incorporating a single machine or overhauling your whole production line — an automated process is most effective when all the supporting elements, such as material handling and personnel, are aligned to complement it.
Even on a small scale, automation can have a significant impact on productivity. Consider the stretch wrapping process: in many operations, this is done manually — once a pallet is built, a worker uses a forklift to pick it up from the line and deliver it to the wrapping station and then to the loading dock. Incorporating even a semi-automatic wrapping unit into the end of line would not only improve speed and productivity, but could also reduce the risk of accidents and material handling issues associated with additional forklift travel. This is just one example of how a half step toward automation could enhance efficiency in your facility.
Let’s take it a step further. Integrating a fully automatic machine into your end of line adds even more production potential, but can get tricky when considering the impacts on the rest of the line. An experienced partner has the knowledge of the other aspects of your line to configure the settings on your unit to integrate smoothly. For example, you’ve installed a high-volume bundler/strapper unit, but have noticed it’s not moving quickly enough to process the boxes coming into it from the conveyor, thus causing a bottleneck. Adjusting the speed settings on the machine to align with that of the upstream processes eliminates this issue and maximizes the production capabilities of your new equipment.
From here, the journey to a lights-out facility can begin to unfold. Discuss these goals with your partner, who can help leverage technology and innovation to continuously refine and improve end-of-line processes.
The Importance of a Strong Team
Prioritizing what part of your operation would benefit most from the automated process can often present the biggest challenges. The seemingly endless possibilities and integration scenarios offered by automation can get overwhelming, especially since buying new equipment affects so many other aspects of the operation. A strong partner will assist in discovering the best solution for your specific operation.
This process typically begins by performing an audit, and looking for inefficiencies to make sure your equipment is optimized to meet production demands — even the most advanced machines may encounter operational issues when not configured correctly. Through a collaborative approach with a good partner, businesses can quickly identify and rectify issues, protecting upstream value and preventing unnecessary downtime.
It’s also important not to overlook your in-house team’s experience and knowledge, as they’ll be on the front lines to troubleshoot any hiccups. Look for a partner who offers training and continuing education to improve the knowledge and confidence of the staff responsible for operating the machinery. Their experience can lead to quicker problem-solving and proactive maintenance, ultimately reducing downtime and increasing productivity.
Your Materials Matter
Understanding how your machinery seamlessly interfaces with your material handling processes is imperative for achieving maximum throughput. In addition to new or updated equipment, the packaging materials you choose can also significantly impact your operation’s overall efficiency. Intentional packaging not only helps secure your valuable product during transport but also maximizes the utilization of space in storage and shipping. Choosing the right protective packaging can minimize waste and reduce the risk of damage, leading to cost savings and a smoother workflow, all while improving handling times and helping your equipment operate at peak performance.
It’s crucial to remember that the manufacturing process is interconnected, and the production line must be adapted to effectively accommodate these material modifications. Consider the example of the bottled water industry. A little over a decade ago, manufacturers began making sustainable choices in bottle makeup — namely cutting the size of the lid in half, and using lighter, thinner plastic/eco-friendly materials to minimize waste and cut costs. Changes like this can actually disrupt downstream production processes, especially in the end-of-line packaging area. In the bottled water example, the material changes ultimately weakened the overall strength of the bottle, requiring an adjustment to the load-wrapping tension to avoid pallet collapse. Choose a partner who has the resources to test the real-world impacts of these changes before you make them, helping you find the most appropriate solution for your specific application.
Tying it All Together
Optimizing performance in a modern manufacturing operation is an ongoing endeavor. Taking incremental steps toward automation can significantly boost efficiency, and a reliable partner plays a crucial role in the smooth transition to fully automated processes. A reliable partner will have years of experience integrating end-of-line solutions across industries, and take a holistic approach to the nuances of each operation. Providing customer resources such as in-house real-world application and factory acceptance testing of new equipment to continuing education and a robust service program is also essential.
About the Author
Joe Albert is the Director of Equipment Sales for Signode. A committed sales leader with 20 years of invaluable experience in end-of-line packaging equipment and consumable manufacturing and sales, Joe excels in solving challenges through consultative, solutions-based strategies, leveraging his vast industry knowledge to deliver strategic outcomes. With two decades at Signode Packaging Systems, and an educational background in Business Management, Sociology, and Economics, Joe’s expertise and education give way to a strong foundation and position him as a leading expert in his field.