Industry Insiders Identify Industrial Engineering Trends
By Sandia Harrison, Director of Marketing, FPE Automation
You Asked: We Answered - Part 3
Thanks for staying tuned to our You Asked: We Answered series of blog posts. This week, we have a whole new group of industry insiders weighing in on what they see as the latest trends in industrial automation. Let's dive in!
Stacey Stowell QC Conveyors
One
of the most impressive trends in automation is the innovation the automation
industry continues to show in responding to labor shortages.
From
repetitive assembly tasks to packaging and palletizing, QC Conveyors has been a
leading performer in creative labor shortage solutions.
Stacey Stowell is in the impressive position of having risen through the ranks at QC Conveyors over the past 20 years to become Director of Channel Sales. That journey has given her a front-row seat as automation has evolved over the past two decades. Stacey has worked with some of the best and most innovative partners in the industry, giving her an excellent perspective on industry trends like these.
Leena Antony FPE Automation
A trend I have seen is an increased interest in product traceability. It is now easier than ever for customers to have a complete record of their product through every step of the manufacturing process. Zebra’s industrial scanners, RFID technology, and industrial barcode readers have given our customers the flexibility to upgrade their current processes with little to no downtime.
Leena Antony is an applications engineer for FPE Automation. It's a role that regularly puts her on the cutting edge of automation as she helps companies engineer next-level robotic and vision systems. Leena is also a certified Universal Robots CORE training instructor and has a Master's degree in industrial technology and operations from the Illinois Institute of Technology.
Nick Hobbs Apera AI
The big thing Apera AI is seeing right now is making existing robotic cells or manual processes better with AI-powered vision. Major automotive manufacturers and Tier 1 suppliers we’re working with have achieved significant productivity gains and ROI. This extends to replacing older vision cameras with processes trained using AI. Manufacturers love these automation projects because production is being interrupted by robot faults or labor shortages, and they don’t have to think about it anymore.
Nick Hobbs has 13+ years of experience in automation sales and leads sales activities for Apera AI. Before joining Apera, he started the Indiana branch of a major systems integrator and grew the territory to be the largest in the company. Nick has a world-class collection of Air Jordan sneakers and is the winner of the Aperagolf long drive competition.
Andy Zaske Tolomatic
Manufacturing will continue to require increasing levels of accuracy, repeatability, control and be environmentally friendly. This will increase the use of electric actuators to replace hydraulic and other fluid power actuators in many aspects of manufacturing. Further accelerating an already growing trend. At Tolomatic, we are also seeing an increasing interest in multi-axis actuator solutions that can be used in applications that require longer reaches or lifting larger loads or faster precision than more typical robots can. This will prove increasingly useful as automation of manufacturing continues to grow and evolve in North America.
Andy Zaske is a seasoned automation professional on the front lines of all things automation. He's not your typical engineer. Friendly, outgoing, knowledgeable and creative, having Andy on your team instantly elevates any project. He is Vice President of Sales and Marketing at Tolomatic, Inc.
Michele Leoni Datalogic Automation srl
Machines are becoming more flexible and able to handle a wider variety of products. As a result, machine builders are looking for devices that can handle multiple scenarios and are easy and intuitive to configure. Datasensing offers superior, easy-to-use products such as the brand new SH4 Series, the world's first Safety Light Curtains that can be programmed wirelessly with an APP
Michele Leoni sends his thoughts from Bologna, Emilia-Romagna, Italy. His perspective, combined with the experience he has gathered as Product Marketing Manager (PMM) at Datalogic, provides us in the midwestern USA with a global view of automation trends.
Read what others had to say.
This is part of the "You Asked: We Answered" series of blog posts, brought to you by FPE Automation. If you missed the others, you can view part one here, and part two here.
Do you work in industrial automation? If so, you probably have your own ideas about where smart manufacturing is headed. Would you like to contribute next time? If so, feel free to reach out to me @sandiaharrison with your brief, two or three-sentence statement and a lighthearted bio like the ones you see here. I'd enjoy hearing what you have to say!
Industry Insiders Identify Industrial Engineering Trends
By Sandia Harrison, Director of Marketing, FPE Automation
You Asked: We Answered - Part 2
Thanks to everyone for your overwhelmingly positive feedback after part 1 of the "You Asked: We Answered" blog series appeared in your social media feeds last week. To recap, it seemed to be ideal timing to ask several individuals at the front lines of automation what they believe to be the biggest emerging trends in manufacturing.
Here's what they had to say this time around:
Zachary Thoma Kawasaki Robotics
I would say it's all about non-proprietary connectivity right now. People don't want to be handcuffed by an OEM's restrictions or recurring licensing fees, they want something akin to the open architecture programming environment that Kawasaki Robotics offers.
Zach Thoma has been improving manufacturing processes and procedures all over the globe for twenty years. He enjoys fitting companies large and small with the right solution and making their processes better. Zach is the creator of the popular podcast series Bot Sh!t Crazy. He is also a strong advocate for mental fitness in the workplace. He is based in Cedar Falls, Iowa, and is Midwest Regional Sales Manager for Kawasaki Robotics USA, Inc.
Kendra Patton Robotiq
Manufacturers are feeling pressure to maintain production while balancing retention rates for employees. We see our customers looking for simple and user-friendly technology that can be implemented quickly without disrupting the current production. Focusing on simplicity for projects, the Robotiq Palletizing Solution continues to be a great fit for these initiatives within various factories. We see implementations that are easily repeated on additional lines within customer facilities which allows standardization throughout the facility.
When the sweeping movement toward collaborative robots (cobots) arrived with unprecedented influential force over the industrial automation industry, Kendra was there. Since then, she has worked with manufacturers on numerous, varied projects to eliminate specific pain points. Using cobots for over half of her career, she understands the market fit and technical needs for applications. As the Palletizing Expert at Robotiq, she focuses on end-of-line deployments using their palletizing solution featuring Universal Robots.
Wes Doty Mech-Mind
We are seeing the continued prioritization of employee retention, and the “up-skilling” of current employees in an effort to retain top talent. We at Mech-Mind Robotics have robust camera hardware, as well as a software suite that is intuitive enough for someone early in their technical career to grasp quickly to make an impact and featureful enough to keep a technical veteran engaged in their personal development, quicker deployment of machines and
overall reductions in hardware costs. It’s truly a win-win for all.
Wesley Doty is best described as a motivational sales strategist, growth driver, player-coach and team builder. He is an experienced national sales leader with a demonstrated history of success in the industrial automation industry. He has a Bachelor of Arts (B.A.) focused in Sales, Distribution, and Marketing Operations, General from Purdue University.
Jomy Vadakumpadam FPE Automation
I am seeing that our customers are looking to partner more
with solution providers rather than purchase their automation products from
re-sellers. They want to work with someone who can provide value more than just
handling the transaction. For example, a robot purchase from Vendor A, PLC
purchase from Vendor B, and a Vision solution from Vendor C can lead to a very
complicated and potentially frustrating timeline to get these three
technologies working together. At FPE Automation, we pride ourselves on being
experts in all of these areas of technology. When you work with FPE, you can
have the confidence that the Panasonic PLC we sold alongside to work with that
Universal Robot and Zebra camera will work together and get set up with minimal
startup/development time.
20 years ago, fresh out of the Illinois Institute of Technology, Jomy Vadakumpadam helped launch the first Automation Controls Division team at FPE Automation. He nurtured the ACD from its origins to the large, talented team of engineers it is today, all the while working with customers large and small to help them automate. For that reason, it's hard to describe the nuances of his considerable experience in the field, or the level of industry respect for his knowledge. Jomy's role is Vice President of Sales & Engineering.
Paul Powers Zebra Technologies
Manufacturers are finding that they cannot ignore automation on the factory floor. For some, what was once an industry term referenced at a conference, is now part of short-term initiatives. With AI-based technology on the forefront of automating processes, we must challenge ourselves to the openness of evolving industrial progressions.
Paul Powers is Senior Channel Account Manager - Machine Vision & Imaging at Zebra Technologies. When first partnered with FPE Automation, Paul's extensive background in automation instantly made him an invaluable asset to our applications engineering team. With a natural talent for problem-solving and a great personality, it's always a pleasure to work with Paul on any vision or imaging project.
Additional Thoughts
I'll continue to reach out to others for their industry trend observations. Stay tuned for round three!
Do you work in industrial automation? If so, you probably have your own ideas about where smart manufacturing is headed. Would you like to contribute next time? If so, feel free to reach out to me, @sandiaharrison, with your brief, two or three-sentence statement and a lighthearted bio like the ones you see here. I'd enjoy hearing what you have to say!
Industry Insiders Identify Industrial Engineering Trends
By Sandia Harrison, Director of Marketing, FPE Automation
You Asked: We Answered
As we approach a packed trade show season, it seemed to be ideal timing to ask several individuals at the front lines of automation what they believe to be the biggest emerging trends in manufacturing. Here are their thoughts.
Barrett White Murrelektronik, Inc.
Machine builders are relying on IO-Link more than ever
before. At Murrelektronik, we pride ourselves in conveying the power of
this technology to our customers. Not only are our customers gaining more
data at the device level, but they are also starting to realize the cost
savings from reduced/simplified wiring, quicker deployment of machines and
overall reductions in hardware costs. It’s truly a win-win for all.
Barrett White is a regional sales manager for Murrelektronik in the states of Wisconsin, Illinois, Minnesota, North Dakota and South Dakota. In his role at Murrelektronik, he focuses on strengthening the connection between the control cabinet and the sensors and actuators in both machines and systems with proven concepts and technologies.
Daniel Kelly Mobile Industrial Robots (MiR)
There is a new trend that was actually an old trend that
didn’t really catch on before COVID. That is Robots as a Service
(RaaS). Manufacturers are still dealing with workforce shortages. And economic conditions are putting an even tighter grip on their
wallets. RaaS has never been more appealing. MiR offers a RaaS
option for our customers through our financing partner to ease that initial
financial hit to their capital budgets.
Dan Kelly had been working in automation for some time. Along the way, he says, it "sparked a new passion in me for robotics and sent me down an exciting path in this industry. I can't wait for all the new adventures headed my way." Dan is a midwestern-based Area Sales Manager for Mobile Industrial Robots (MiR).
Brittany Carroll IRIS Factory Automation
A
trend we have seen with our Manufacturing customers is that this new generation
is moving away from labor-intensive roles.
IRIS Factory Automation has developed Automation solutions
to combat repetitive high-labor jobs. In this, we have designed an appealing and
easy-to-use interface and system to attract and retain employees with a more
fulfilling role.
Brittany Carroll has dedicated her career to creating long-lasting relationships with partners and clients. She is a content creator and the host of the Automation Happy Hour Podcast. Brittany is a Channel Partner Manager at IRIS Factory Automation.
Scott Massie FPE Automation
Two of the biggest trends I see in manufacturing are I/O Link
and electric actuators. I see engineering teams moving away from older solutions toward both of these, and getting far better performance across the board.
Mac Valves has recently released their MIO-Link
product, which takes a stack of valves and communicates on the I/O Link
network….saving wiring time and troubleshooting time.
PHD Inc. has a broad
line of long life electric actuators that have solved a large number of
difficult applications in the marketplace for us.
Scott Massie is an experienced regional application expert with highly specialized product training in several key areas. Although he wears many hats, his official title is Sales Manager, FPE Automation.
Michael Walchli Universal Robots
Due to the shortage of welders in the industry, collaborative robots are rapidly growing into the welding space. Universal Robots have taken their knowledge and utilized their partner network to fill the void with collaborative automated welding solutions.
Michael Walchlii has developed an established career in the mechanical and industrial engineering industry. He is a Channel Development Manager in the midwestern USA for Universal Robots. Prior to that, he served as an infantryman in the US Army,
Additional Thoughts
I'll continue to reach out to others for their industry trend observations. Stay tuned for round two!
Do you work in industrial automation? If so, you probably have your own ideas about where smart manufacturing is headed. Would you like to contribute next time? If so, feel free to reach out to me, @sandiaharrison, with your brief, two or three-sentence statement and a lighthearted bio like the ones you see here. I'd enjoy hearing what you have to say!
Across the Country, Limestone Processing Plants Are Reducing Their Carbon Footprint with MAC Pulse Valves
The Mississippi River Source: Mississippi Lime
By Sandia Harrison, Director of Marketing, FPE Automation
In a concerted effort to combat climate change, limestone processing plants across the country are taking significant steps to reduce their carbon footprint. One innovative solution gaining traction in the industry is the installation of MAC Pulse Valves. These valves are revolutionizing the way dust collection systems operate within these facilities, leading to substantial energy savings.
Limestone processing used to be notorious for its environmental impact, primarily due to the energy-intensive nature of lime production. However, with the introduction of MAC Pulse Valves, the industry is undergoing a transformation. These valves efficiently control the dust collector systems, vastly reducing the time they operate. By doing so, they not only enhance the overall efficiency of the process but also significantly cut down on energy consumption. All while keeping the air the workers breathe clean.
Clean production due to a more efficient dust collection system.
Across the board, virtually all limestone processing plants in the United States have made a commitment to sustainability.
The adoption of MAC Pulse Valves is a testament to the industry's dedication to environmental stewardship. As limestone processing plants across the nation embrace this technology, they are not only improving their environmental footprint but also setting an example for other industry sectors. With such innovations, the future of limestone processing looks greener, aligning with the broader goals of reducing carbon emissions and safeguarding our planet's health.
At FPE Automation: assembling, inspecting and testing the more efficient valves prior to installation.
Retrofitting a Dust Collector: What's Involved?
Retrofitting a dust collector involves several key steps, starting with an assessment of the existing collector's performance and condition. Inefficient valves stick, break down frequently and run continously, wasting energy without properly cleaning the air. Corrosion is a common issue. The valves pictured here have anti-corrosion nickel plating that was developed specifically for the harsh environment in lime plants.
Fortunately, tools are available to measure and compare one solution over the other, and to properly size your application. FPE Automation has in-house specialists who are highly skilled in assessing dust collection systems They can collect and present factual data from your environment that can help you to make the correct determination. Once the evaluation is complete, the goal is to enhance the dust collector's performance, reduce energy consumption, and ensure compliance with environmental regulations, making it an essential undertaking for industries reliant on effective dust management systems. Many of the nation's largest limestone miners have reached that goal by adopting MAC Pulse Valves technology as part of their clean air initiatives.
Do you work in industrial automation? If so, you probably have your own ideas about where smart manufacturing is headed. Would you like to contribute next time? If so, feel free to reach out to the author of this post, @sandiaharrison, I'd enjoy hearing what you have to say!
On the Road Again: Robotic Gripper Application at a Major Car Tire Manufacturing Plant
FPE Automation's Andy Button receives recognition for the implementation of custom robotic grippers in the manufacturing plant of a global tire manufacturer.
By Sandia Harrison, Director of Marketing, FPE Automation
Car tires. Where the proverbial "wheels hit the road." It's where every journey starts. Or is it? Most of us have never given any thought about the journey every tire makes before it ends up on our car. It turns out that AI-driven robots are revolutionizing the automotive industry, particularly in the domain of car tires, resulting in substantial efficiency gains.
I reached out to Travis Haynes, Senior Application Engineer at PHD Inc. "The customer wanted a three-jaw gripper, as the concept they’ve used before involved a cylinder driving three pivoting arms to retain the tire," he told me.
The goal: To pick and place tires of various sizes by their internal diameter.
Simulation only: actual drawing not used to maintain confidentiality.
The application: A robotic cell that can detect the tire size from the ID on the tire using machine vision, and automatically grip and lift it.
The challenge: The difference in tire sizes called for significantly more travel than a standard three-jaw gripper has available.
So, Hayes, together with Andy Button, Regional Sales Team Leader at FPE Automation, and with the help of a local integrator, looked at custom solutions.
"This gripper is the result of adding backing plates to a previous custom design to increase jaw moment capacities." Hayes described. "It is effectively a customized, three-jaw version of PHD's popular GRR gripper."
FPE Automation's Andy Buton (R) and me.
The gripper is used as end-of-arm-tooling (EOAT) on a robot, which is part of a production cell. The resulting engineered solution significantly optimizes the process for the tire manufacturer.
"The standards were set very high for this project." Button told me, "There was no room for errors or inaccuracy. The PHD custom team made the process seamless. The end result was that the customer has exactly what they wanted. These robot cells will work out very well for them."
Car Tire Innovation
We can all expect to see more news in the upcoming months about robotic cells and AI being used for the manufacture of car tires. As manufacturing plants automate, quality increases. So does safety and reliability. The automotive industry has a long history of leading the way when it comes to manufacturing innovation. Typically, it's not long before other industries follow suit.
If you would like to know more about how you can use AI and robot cells to streamline your operations, reach out to the experts FPE Automation. We can arrange to take you on a tour of one of our state-of-the-art robotic and vision labs or set up a demo. Or, we can stop by and visit you. We're local.
A Job Well Done
Congratulations to FPE Automation's Andy Button, who received accolades in this month's industry newsletter from PHD Inc. for his hard work on this project. Hats off to Travis Haynes as well, for his innovative design.
FPE Automation is a preferred PHD Inc. partner. Whether it is their high-quality, robust off-the-shelf products, or a custom solution like this one, we can help.
Recognizing Unseen Heroes: Honoring the Contribution of Female Veterans of the U.S. Military
Event coverage by Sandia Harrison, Director of Marketing, FPE Automation
PLAINFIELD, IL. Over this past weekend, AllenForce's "All In For Veterans Charity Ride", a motorcycle ride to honor the female veterans who bravely served our country.
These incredible individuals, soldiers who are sometimes overlooked, are so very worthy of honor and support. They have saved lives and preserved our freedom right alongside their male counterparts. We salute you.
The AllenForce team had this to say, "Our annual event includes a ceremony honoring a specific group of people from the military. This year [2023], we are honoring Women of the Military, the 75th Anniversary of the Women's Armed Services Integration Act. On June 12, 1948, President Truman signed into law this Act, allowing women to serve as permanent, regular members of the Armed Forces."
"Thank you to FPE Automation and ALL of our sponsors and supporters of our All In For Veterans Charity Ride honoring Women Veterans."
FPE Automation is a longtime supporter of this (and other) worthwhile charities in the community we serve. We're local in our roots, midwestern since 1963. The health of jobs, families and manufacturing in Illinois, Missouri and Iowa are important to us to the core.
#AllenForce #charity #sheforce #fpeautomation #fpegivesback #militarywomen #womenveterans #usa #companiesthatcare #rideforcharity
By Sandia Harrison, Director of Marketing, FPE Automation
In today's post, let's tackle a question that is arguably one of the most difficult in manufacturing
If Shakespeare were alive today and working in production ops, instead of the famous quote, "To be or not to be," he might ask, "In-house or not in-house?" This, folks, is as close as we come in manufacturing to an "existential question".
What should you produce, and what should you outsource? When is it worthwhile? Are there times when it's a bad idea? And why, throughout the decades, has this remained such a challenging topic?
Let's break it down.
First, why can't you find a clear answer?
Even using the most sophisticated artificial intelligence (AI), you have probably already discovered that you won't find a simple answer online. We are all practically bombarded by webinars, industry publications, and blog posts. Sure, you might come across some very helpful information. However, there are too many variables. One size does not fit all. What works well for another manufacturer might not work at all for you.
You could bring in vendors, consultants, and reps. Maybe you already have. You can schedule appointments, have them stop by, and listen to their pitch. They are probably helpful - to a point. They'll tell you that they can produce sub-widget x for a specific price. You might know how much that item costs you to produce. You might not. It can be tricky to calculate. Or, you might be looking at the wrong sub-widget entirely. It's nearly impossible to tell.
It's an open-ended question with too many valid answers.
Assuming you do know the exact cost for you to manufacture the sub-assembly, and you are confident that it is the ideal spot in your manufacturing process to consider outsourcing, there are still several other factors in play.
Who can produce the item more optimally? Sometimes, having the parts come off one assembly cell and immediately brought to the next one can help optimize your production. For some, it creates a bottleneck. Be careful not to lose sight of the bigger picture. Your goal is not to outsource. Your goal is to streamline your operations. If it doesn't do so, look elsewhere.
How specialized is the item? Certain highly specialized items might be a "custom" even for an expert in that particular area. Do the size, design, or other characteristics make it a good fit for outsourcing? If you can purchase an off-the-shelf item that is a drop-in replacement, it will often be your best choice. Protecting your intellectual property is a priority. There are certain items you may not want to outsource to protect trade secrets and avoid sharing confidential design details.
Are you facing longer production times and other interruptions? If you're short on bandwidth, it can be a lifesaver to outsource an item. On the other hand, it adds an additional layer of delivery and potential delays that someone at your company will need to manage.
Can you make it better? Or not as well? Quality and consistency are key, of course.
Factoring in labor costs: Do your employees have the knowledge and time to manufacture them? Will it involve overtime or delay production?
Do you have the space to store the items? You may be able to roughly calculate how many sub-assemblies you would need on your shelves to get you through a day/week/month/quarter. Do you have the physical space/square footage to both manufacture and store the item until it is ready to use?
Do you have the equipment and production space? Perhaps you have aging, inefficient machines. When they break down, will it be cost-effective to invest in new ones? If you were to discard, sell, or write off that machinery, could the floor space be used for higher-value processes?
Transportation costs: If you are able to outsource the items nearby, you may be in luck. If there is no local supplier, it might be very costly to get the goods to you from a distant location.
While you were reading this list, did a specific pain point in your production process cross your mind? If so, you might have just discovered a great candidate for outsourcing. Still not sure? Here are some things to consider.
Value-added services like those provided by FPE Automation offer flexibility in manufacturing operations. Our specialized teams are well-equipped with the necessary expertise and equipment to handle specific tasks efficiently.
Countless manufacturers in the region have partnered with us for specialized sub-assembly. This is some of the actual feedback we receive.
Expertise and Specialization:
"I can rely on FPE Automation's knowledge and skills. They have been a key contributor to our initiative to produce higher-quality products and make our processes more efficient."
Cost Efficiency:
"For us, outsourcing certain production stages to FPE Automation has led to cost savings due to streamlined processes, reduced waste, and optimized resource utilization."
Focus on Core Competencies:
"Partnering with FPE Automation has allowed us to focus on our core competencies while leaving other manufacturing tasks to the experts in that niche area."
Innovation:
"FPE Automation'sHandshake Solutions team is more up-to-date with the latest technologies and innovations than we have the ability to be. Working with them gives our medium-size manufacturing company access to cutting-edge solutions without heavy R&D investments."
Scalability:
"Collaborating with FPE Automation gives us the flexibility to scale production up or down based on demand fluctuations, reducing added costs associated with fixed production capacities."
Time Savings:
"Our value-added partner, FPE Automation, works with us to meet our production deadlines."
Enhanced Product Quality:
"The boost in quality and consistency we saw when we partnered with FPE Automation's value-added team has truly allowed us to make a better product."
Saving Labor:
"Embracing automation and efficient processes can significantly save labor costs. By automating repetitive tasks and utilizing advanced technologies, we can allocate our resources to more creative and strategic roles, ultimately boosting productivity. FPE Automation'sHandshake Solutions team is friendly and knowledgeable - a pleasure to work with."
Ease of Ordering:
"By creating highly specialized kits, FPE Automation's value-added team has turned various components into easily manageable ordering units. They're happy to accommodate our own part number and can build items others can't. For us, that has really simplified our purchasing experience. It reduces confusion, minimizes errors, and accelerates the order fulfillment process."
You're in capable hands with both of FPE Automation's manufacturing partners.
Relying on the right manufacturing partner has advantages. At FPE Automation, we have two separate divisions to do the job. Our value-added team can efficiently assemble products that may be challenging and inefficient for you or even for other third-party subassemblers. Tried and true, they regularly eliminate many of the pain points discussed in this article. Manufacturers have relied on our value-added services for more than 60 years.
Our Handshake Solution team specializes in engineered solutions and turn-key automation. For robot cells, vision systems, palletizers, and more, they are your highly regarded, go-to source you can add to your process to optimize production.
Because this is a much bigger topic than a simple article can address, FPE Automation is here to help you tackle it. Reach out to us for an introduction to our teams. Let's start a dialogue. We exist to help you reach (and exceed) your production goals, hence our motto:
What you do is what we do.
For more information about value-added and sub-assembly services, visit the Design/Assemble page on our website. For our Handshake Solutions division, which delivers robot cells, vision systems and other ready-to-implement solutions, you can learn more here. Or, you can reach out to us directly here.
Here are some helpful suggestions to optimize your factory automation journey - and a few to avoid.
This month’s featured article is a helpful do's and don't's for anyone in automation controls, production management, or maintenance. Packed with valuable tips, condensed into a 2-minute read. What could be better? I hope you enjoy it!
By Sandia Harrison, Director of Marketing, FPE Automation
Does your inbox look like word salad or verbal spaghetti?
"Word salad" and "verbal spaghetti" are funny ways that overwhelmed middle managers have come to describe the endless corporate jargon that comes their way. Defined as a mix of nonsensical words and phrases, unfortunately, a lot of what hits our inboxes falls into that category.
Do you run across phrases like these?
achieving efficient workflows
reducing labor costs
enhancing product quality
minimizing waste
supporting sustainability efforts
All of these are hot topics in manufacturing that have been in the news for quite a while.
You have probably noticed these industry trends - on repeat.
More than words.
Jargon aside, these topics are being discussed for good reason. They're crucial aspects of improving competitiveness and profitability for your company.
The trick is to make it all happen. Easier said than done?
Good news! They are goals that may be more attainable than you realize.
DO use technology: leverage IoT and sensor technology to monitor component health in real time, and for controls. Predictive maintenance allows proactive identification of potential failures, reducing unplanned downtime and production disruptions. Software-driven automation is predictable and accurate.
DO regular performance analysis: Continuously assess component performance through data analysis. Identify areas for enhancement and collaborate with engineering teams to implement design or material changes.
AVOID reactive maintenance: Refrain from relying solely on reactive maintenance. Waiting for components to fail before taking action can lead to costly downtime and production delays.
Reaching your goals.
Do stock spare parts strategically: You don't need a degree in supply chain management to maintain an organized inventory of critical spare parts based on usage trends and component lifecycles. Smart use of the reporting tools you already own should help you to minimize excess stock while ensuring the availability of the components you need to prevent prolonged downtime. If all else fails, FPE
Automation has millions of items on the shelves and ready to deliver. We can also help you get things in a pinch.
Don't neglect aging components: Neglecting aging components can result in unexpected failures. Regularly evaluate the condition of components nearing the end of their lifecycle and plan for timely replacements or upgrades.
Do consider collaborative robots: Consider collaborative robots (cobots) for enhanced efficiency. With safety features and versatility, cobots (like the one pictured on the right by Universal Robots), excel in pick and place, machine tending, packaging, process tasks, finishing, and quality inspection. They operate reliably around the clock. They work safely alongside humans with no guarding needed. Cobots can boost reliability in more ways than you may realize.
Do take lead times into account: Since COVID, lead times have been all over the board. When planning, remember to consider the duration between order placement and product receipt. Lead times impact production efficiency and, ultimately, customer satisfaction. Manage various factors, such as material procurement, production, and shipping times, to optimize your processes and ensure timely delivery.
Avoid Siloed Processes: Don't keep processes isolated. Integrate all aspects of production, from planning and scheduling to execution. This promotes seamless communication and efficient coordination.
On the other hand, don't rule out production cells: When looking at your production with an integrated approach, don't underestimate the value of robot cells. Engineered for the specific products or parts they produce, robot cells can often be as close to a perfect solution as technology allows. They enhance material flow efficiency, communication, and waste reduction, yielding significant benefits for manufacturing processes. Check out our Handshake Solutions, where you can personally create your own concept at any level you feel comfortable.
Similarly, skip Traditional Production: Don't rely solely on traditional mass production. Embrace flexible manufacturing systems to handle diverse product variations without compromising efficiency. Well-thought-out integrations allow quick changeovers and can accommodate varying demand.
In certain cases, consider using a Certified Systems Integrator (CSI): Consider leveraging the expertise of a Certified Systems Integrator (CSI). With technical expertise and business knowledge, CSIs uphold the highest standards, offering proven track records. They have already tested the solutions, so you don't have to. New integrations can be a huge time commitment for already busy production engineers and maintenance managers. Hiring a CSI can help alleviate most of that burden while
giving your staff the peace of mind that critical automation projects are in capable hands. FPE Automation can work with you, or help partner you with a qualified CSI.
Avoid rigid automation: Steer clear of fixed automation for processes that would perform better with some adaptability. Programmable automation provides versatility by accommodating different products and batch sizes. Agility is key.
And finally, choose the right partner: FPE Automation has an award-winning, in-house, team of engineers to assist you. We inventory large quantities of the products you need most. When we make recommendations, you can be confident that have your best interest in mind. Your success is our success.
New levels of productivity.
Incorporating these principles will propel your operations into the future of automation, where
interconnected systems, data-driven decisions, and agile manufacturing redefine efficiency and productivity.
By adopting these practices, maintenance managers can optimize manufacturing component management, enhance equipment reliability, and contribute to the overall efficiency of the manufacturing process.
FPE Automation is here to help.
From the smallest to the largest companies in the midwest, we have longstanding relationships that have stood the test of time.
When there is a
lot on the (production) line, we have experts who can:
team up with you to create effective solutions
send in experts to assess your needs and report back to you
put you in contact with a certified systems integrator (CSI), and help you to work with them to deliver exactly what you need
Whatever your needs are, FPE Automation has been here to help you manufacture smarter since 1963.
Important Automation Trends Worthy of Your Attention
By Sandia Harrison, Director of Marketing, FPE Automation
Just a short time ago, it was hard to imagine being in the midst of an automation revolution. Yet here we are. It's an exciting time to be in manufacturing! Still, as summer winds down, and we approach the fourth quarter of 2023 and start thinking about (wow!) 2024, it's time for a quick recalibration. Things are moving fast. Let's slow down for just a moment to focus on the pulse and trajectory of automation in the months to come.
Staying on Track
Industrial automation trends for the 4th quarter of 2023 are driven by innovative technologies that enhance efficiency, productivity, and safety in various industrial sectors. These trends encompass a range of advancements, each playing a vital role in shaping the landscape of automation.
It's important to keep our eye on the prize. It really is all about efficiency and the bottom line. We know we need to automate. Let's make sure we're smart about it.
Here are some key trends to watch - and some to move away from.
Moving Toward: Increased Leveraging of Collaborative Robots
Collaborative robots, or cobots, continue to dominate the industrial automation scene. Universal Robots work alongside humans, offering benefits such as flexibility, safety, cost-effectiveness, improved productivity, and ease of use. Equipped with advanced sensors and software, cobots can detect human presence, movement, and touch. This capability ensures their safe interaction with human coworkers, making them an invaluable asset in many industries.
Here are just a few of the vertical markets where cobots are making a significant difference in companies' bottom lines:
packaging automation
pick and place
welding and fastening
sanding and grinding
deburring, cutting, trimming
CNC and machine tending
material handling
finishing
dispensing
Moving Away From: Dependence on Legacy Systems
Relying on outdated legacy systems can limit flexibility, scalability, and integration capabilities. Manufacturers can greatly benefit from transitioning to modern solutions that offer greater agility, accessibility, and scalability for their operations.
Moving Toward: Vision Systems
Vision systems are another significant trend in industrial automation for 2023-24. These systems utilize cameras, sensors, and algorithmic software to inspect and analyze parts and products in real time. Vision systems, like those made by Zebra Technologies enhance quality control and eliminate human error, as they can inspect products faster and with greater accuracy. They can be seamlessly integrated at various points along the production line, providing valuable insights into the manufacturing process.
Simply put, now and into the future, vision will be used wherever quality matters. You might be thinking, "quality matters everywhere", and of course, you would be correct. While it would be impossible to include them all, here's a partial list of industries where vision gained traction this year and where we expect the trend to continue in 2024:
electronics manufacturing
food and beverage
automotive
pharmaceuticals
aerospace
consumer goods
metal and machinery
textile and apparel
plastics and rubber
Moving Away From: Manual Processes
Traditional manual processes can cause errors, slow down operations, and hinder real-time decision-making. In order to stay competitive, manufacturers need to find ways to embrace automation to enhance accuracy, efficiency, and productivity. However, one size does not fit all. Intelligent automation is key.
Moving Toward: Autonomous Mobile Robots (AMRs)
AMRs have continued to emerge as a major automation trend in 2023. Robot carts, equipped with sensors and advanced computing capabilities, navigate industrial spaces autonomously. Unlike Automated Guided Vehicles (AGVs), AMRs offer greater flexibility and adaptability, moving in any direction and adjusting their behavior based on real-time analysis of their environment. Mobile Industrial Robots (MiR) are becoming a popular choice for optimizing efficiency in manufacturing and packaging processes.
These are a few key areas where AMRs continue to quickly gain popularity due to their effectiveness:
distribution centers and order fulfillment
warehouses
cleaning and disinfection
hospitals and healthcare facilities
manufacturing
safer internal transport of heavy loads
loading/unloading
Moving Away From: Dated Approaches to Maintenance Planning
Failing to implement proactive maintenance practices and relying on reactive maintenance can lead to increased downtime and higher maintenance costs. This is a key area where directors, owners, and managers should take note. It is to your benefit to empower your maintenance managers. Encourage them to shift towards predictive and preventive maintenance strategies, leveraging the latest technology to optimize equipment performance and minimize disruptions - before they happen.
Moving Toward: Industry 4.0
Industry 4.0, often referred to as the fourth industrial revolution, emphasizes the integration of technologies like AI, big data, the Internet of Things (IoT), and robotics. These technologies work together to increase productivity, monitoring capabilities, and flexibility in production facilities. Real-time data monitoring and communication, enabled by interconnectivity, are at the core of Industry 4.0, empowering industries to make informed decisions and respond to market changes promptly. Experts like those in FPE Automation's Handshake Solutions division are able to combine these technologies to create turnkey systems or intelligent robot cells to help companies leverage the technology.
A "robot cell" or "turnkey solution" in manufacturing refers to an automatic work cell that incorporates one or more programmable robots along with grippers, tooling, programming and other automation. Both collaborative robots (Universal Robots) and traditional industrial robots (Epson, Kawasaki) can be used, depending on the application. By addressing a single production need with an all-encompassing, start-to-finish approach, they enhance the production process overall by maximizing efficiency, speed, and repeatability of product quality. The result is a highly advanced and integrated solution designed to optimize specific manufacturing tasks and operations.
There are many benefits.
Cost-Efficiency:
replaces expensive labor
works quickly, boosts production
economical, when compared to separate equipment or manual labor
Improved Production Rate:
rapid and repeatable tasks
higher-quality products, more consistent quality
satisfies customers, increases revenue
Reduced Downtime:
continuous workflow
quick application changes
minimizes production losses
All-in-One/Turnkey Solutions:
Customized automation
Made for your specific manufacturing process
simplifies automation needs
Moving Away From: Obsolete Equipment and Parts
Continuing to use obsolete equipment and components can result in higher maintenance expenses, longer downtime, and decreased productivity. Manufacturers should invest in modernizing their equipment, utilizing predictive analytics to identify and replace aging components before they fail.
Moving Toward: 3D and 4D Vision Technology for Robotic Automation
The convergence of machine learning and automation brings unprecedented control over operations. Machine learning applications are groundbreaking. Companies like Apera AI and Mech-mind are advancing robotic automation through the development and implementation of cutting-edge vision technology. They both contribute to making enable robots to perform tasks with human-like speed, sight, and perception, giving them ever-increasing precision and intelligence.
The latest innovations have been groundbreaking in areas such as:
bin picking
packaging
assembly
part sorting
machine tending
kitting
palletizing/de-palletizing
inline measurement
What You Do is What We Do
These automation trends showcase the continuous evolution of industrial processes, driven by technological advancements that enhance efficiency, accuracy, and safety across various sectors. As businesses embrace these trends, they position themselves to stay competitive and adapt to the changing landscape of industrial automation. At FPE Automation, whatever it is that you need to accomplish, it's our job to help you achieve your automation goals.
FPE Automation is celebrating its 60th anniversary; 1963-2023. Imagine how much industrial automation has changed over the past six decades!
Do's and Don'ts: Unleashing the True Potential of Machine Vision
By Sandia Harrison, Director of Marketing, FPE Automation
In the ever-evolving world of technology, businesses and industries have a real need to consistently seek innovative solutions to enhance efficiency, productivity, and overall performance. Put simply, if they don’t, they won’t remain competitive for long.
Machine vision and barcode scanning technology help companies do just that. Innovations by companies like Zebra Technologies have emerged as powerful tools for solving a long list of pain points that are commonly associated with old-school manufacturing.
Here are just a few of the many benefits:
Enhanced quality and process control
Detection of visual inconsistencies in labels, packages, and item designs on production lines, minimizing defects that could lead to returns, noncompliance penalties, and other financial losses
Automated inspection
Streamlining and process improvement
Real-time visual inspections of items as they move down the line
Trackability/traceability
Improved operational visibility
Compliance with regulations
However, amid the excitement of adopting cutting-edge solutions, many customers often fall prey to certain misconceptions and pitfalls that can hinder the full realization of the technology's potential.
Not Taking Full Advantage of the Customization Potential
One prevalent misconception among many companies is the assumption that machine vision solutions are one-size-fits-all. FPE Automation has a team of experts that can offer you a higher degree of flexibility, allowing your business to tailor the solutions to your unique environment and application. By understanding your specific needs, our team can work with your engineers to harness the full power of customization and achieve optimal efficiency in your operations.
Not Fully Understanding the Process in Advance
Adopting machine vision technology is a transformative journey. While Zebra's range of mobile computers, barcode scanners, and RFID readers are indeed powerful, successful implementation requires careful planning, integration, and adaptation. The right approach ensures a smoother transition and long-term success. At FPE Automation, it is our role to assemble the right team to do the job. We can involve top industry talent and, if necessary, pull in our own Handshake Solutions team to help you achieve your goals.
One inspiring success story comes from a leading e-commerce giant that was struggling to optimize its warehouse operations. Facing challenges in inventory management, order accuracy, and overall efficiency, the company turned to Zebra's industrial machine vision and fixed scanners.
Upon partnering with Zebra's experts, the e-commerce giant underwent a comprehensive evaluation of their warehouse layout and operational workflows. The Zebra team collaborated closely with the customer to customize a solution that perfectly aligned with their specific needs.
Through the seamless integration of machine vision technology, the organization's upper management witnessed a remarkable transformation. Real-time tracking and accurate data capture minimized errors in order fulfillment, leading to increased customer satisfaction. The ability to tailor the solution to the warehouse environment maximized efficiency and boosted productivity.
Zebra's machine vision technology offers immense potential for businesses across diverse industries. To truly unlock its power, companies must steer clear of common misunderstandings and misconceptions. By embracing customization, managing expectations, and assembling the right team to do the job, businesses can harness the true potential of Zebra's cutting-edge solutions.
We Live in a World Where Manufacturing Excellence and Operational Efficiency Matter More and More
Partnering with FPE Automation for your machine vision and barcode scanning needs is a strategic choice that ensures your company stays ahead of the curve. With a genuine commitment to simplifying complexity, FPE Automation, in collaboration with Zebra, offers an unparalleled solution that transforms fixed scanning and machine vision into streamlined, accessible processes.
Zebra's groundbreaking hardware and software platform, backed by decades of industrial leadership, empowers you to unlock new levels of productivity and precision. Whether you're a novice or an expert, FPE Automation's expertise ensures a smooth journey, from setup to execution, enabling your company to seize the benefits of Zebra's game-changing innovation. Embrace the future of industrial automation with confidence as the engineers at FPE Automation work with your engineers to pave the way for your success.
By Sandia Harrison, Director of Marketing, FPE Automation
You may have heard about the highly-anticipated MIO-Link™ launch. It is MAC Valves' new total connectivity fieldbus solution. Today I'm partnering up with FPE Automation's Colton Rentsch, Automation Engineer, to delve into the functionalities of MIO-Link™ and explore how this latest technological advancement can elevate your automation.
What is MIO-Link™?
At its core, MIO-Link™ is an innovative I/O Link device that leverages state-of-the-art technology to redefine Fieldbus. Built to be the ultimate, single cable, point-to-point solution, these devices offer exceptional versatility, performance, and diagnostics capabilities, making them a game-changer for industries seeking precision and efficiency. Using just one cable, you can isolate communication and power to individual pins easily integrated into a machine safety circuit. This single cable solution greatly reduces setup time and wiring needed for valve connection.
Made by MAC Valves in Wixom, MI, MIO-Link™ has patented MAC quality built into every manifold.
Unleashing the Power of MIO-Link™
Let's take a closer look at the key features that make MIO-Link™ an indispensable asset for any automation setup.
I/O Link Master Integration
MIO-Link™ seamlessly integrates with I/O link masters for its operation. This integration ensures smooth communication and coordination between devices, optimizing the automation process.
Scalable Solenoid Channels
With up to 32 solenoid channels, MIO-Link™ provides unmatched scalability. Whether you are managing a small-scale application or a complex industrial process, this device has you covered.
Comprehensive Diagnostics
MIO-Link™ doesn't just automate; it empowers you with vital information. The device reports diagnostics information to the master, including critical parameters such as open circuit (no load), over current (short circuit), under voltage, over-voltage, and over temperature. This proactive approach enables efficient troubleshooting and minimizes downtime.
Available Models
MIO-Link™ is compatible with MAC Valves' 36, 42, 46 and 92 series valves, with other series available upon request. Use them with any Fieldbus platform, including Ethernet IP, PROFINET, EtherCAT, and more. MIO-Link™ comes in two distinct models - Class A and Class B - each tailored to meet specific requirements:
Class A Model
The Class A model draws power for its electronics from the master and power for valves from an additional M12 connector. With 2x M12 connectors (I/O link & power), it is compatible with Class A and Class B masters.
Class B Model
In the Class B model, both electronics and valves draw power from the master. The master supplies up to 4A maximum total for all devices attached to it, ensuring seamless functionality. The Class B model features a 1x M12 connector and is designed to be compatible with Class B masters.
Engineering-friendly and Ready to Operate
Are you ready to take your operations to the next level? MIO-Link™, available at FPE Automation, is the gateway to enhanced productivity, efficiency, and precision. To begin your automation journey with MIO-Link™ and explore the endless possibilities it offers, reach out to FPE Automation for a personalized quote and additional information. Our team of experts is dedicated to providing top-notch solutions that propel your business forward.
MIO-Link™: Embrace the Future of Automation
MIO-Link™ stands at the forefront of automation innovation, ushering in a new era of seamless connectivity and intelligent solutions. As industries evolve and demand efficiency, FPE Automation's MIO-Link™ sets the standard for I/O Link devices, driving progress and transforming how we perceive connectivity.
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