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.
Celebrating Excellence: MAC Valves Announces FPE Automation is Winner of Distributor of the Year Award for 2022
By Sandia Harrison, Director of Marketing, FPE Automation
Breaking news: July 6, 2023, Wixom, Michigan
MAC Valves announced today that FPE Automation is the recipient of their Distributor of the Year award for 2022. It is the company's unprecedented fourth time receiving the coveted award.
We are incredibly thrilled and humbled to announce that FPE Automation has been honored with the Distributor of the Year award. It is with immense pride that we share this remarkable achievement with each and every one of you who has played an integral role in our success.
MAC Valves manufactures a superior, patented product in a class of its own. While that's undoubtedly true, this particular success is, in no small part, a result of new and innovative ways to address manufacturing pain points and save costs using the latest technology.
"Throughout the years, FPE Automation has continued to evolve, adapt and grow alongside MAC Valves and have had great success in doing so. We have constantly championed the technology that MAC has provided and have taken a leadership role since the inception of the MAC Distributor Network (MDN)."
MDN is a global organization of independent distributors and manufacturers with the common focus of customer service and support at any time, anywhere in the world.
"David Bardos, CEO, was an integral part in the formation of the MDN. He and I continue to help lead and grow this best‐in‐class, irreplicable group," Bardos continued.
"Our strong relationships with our customers and our long-tenured and loyal employees have allowed us to go out and present new innovations that are transformative to manufacturers and helpful to their bottom line. This win was truly built one purposeful conversation at a time."
"They are strategic conversations that pool from our resources to determine the next action steps needed for success."
"Our success in 2022 was not just a result of doing what we have always done. Adding specific technology specialists was a major kick‐start to rapid growth. Scott Massie, whose 20+ years of knowledge in the MDN and the pneumatics industry is second to none, has been instrumental in not only assisting in market share gains but mentoring a new wave of specialists and helping to instill the MAC DNA that FPE Automation embodies. Along with Scott, our entire management/ownership team understands that it takes a cohesive unit to identify and start projects and see them to the finish line. We meet weekly to go over major projects. Those meetings are not just a rehashing. Rather, they are strategic conversations that pool from our resources to determine the next action steps needed for success."
The new growth we have been experiencing recently has come from our ability to capitalize on what we know and do well. We have long had success in industries such as transportation, food/beverage, and packaging. At the same time, we have found ways to go wider and deeper into streamlining operations utilizing the latest technology and newest innovations."
"Still, the secret sauce lies in our people. It comes back to attitude and activity. We preach that these are the only two things you can control, and our entire team works hard, works together, works often, and goes about it in pursuit of success. We also have a great time doing it! We hope to continue that driving forward."
The award was announced by Matthew Neff, President & COO, and Joseph Richardson, Vice‐President of Sales at MAC Valves, with their congratulations on what they called a "tremendous success".
Once again, we extend our heartfelt gratitude to everyone who has contributed to our success. Your support has been invaluable, and we look forward to celebrating this remarkable achievement together. This award is a reminder that together, we can accomplish great things.
Thank you for being part of it all. Wherever innovation takes us next, we look forward to the journey.
Minor savings in energy costs can result in added costs and risks elsewhere. Dust collectors have options.
By Sandia Harrison, Director of Marketing, FPE Automation
"Consider This - Single Energy Projects Don't Maximize Savings"Industry Week reports. If you've been a part of a corporate energy initiative, you might have found that statement to be painfully obvious. Lots of effort to save a few hundred dollars. Sound familiar?
For manufacturers, there are big motivators to save energy. For several years, in the U.S., tax incentives were in place to entice corporations to reduce their energy consumption. The dollar savings (read: bottom line on the company's energy bill) is another good reason to reduce costs. Sustainability and going "green" are increasingly important aspects of operating in today's business climate.
So, manufacturing plants everywhere adopted measure after measure in their quest to re-think the way they consume energy. As you would expect, some worked better than others. Those mixed results were confusing.
For many plant managers, energy-saving efforts like building improvements were at the top of their list, in terms of priority. Better insulation, energy-efficient windows, smart light switches and roofing systems certainly do reduce heating and cooling loads. The problem is, upgrades like those involve significant upfront costs, which can diminish or even completely nullify, their effectiveness, creating a false economy. Add an increase of labor costs and disruption to ongoing operations, and suddenly they don't seem very appealing.
In fact, most of the items in the top 10 list of so-called "improvements" cost more money to implement than they saved. FPE Automation meets with companies on a daily basis, and the conversation is always similar. You are not getting enough "bang for their buck". We hear you. You are trying. Quite frankly, you're a bit frustrated.
So, how do you really reduce your carbon footprint without increasing costs? How do you do so in such a way that it produces measurable results?
A factory worker climbs a ladder to replace older, malfunctioning diaphragm valves in inclement weather.
It turns out, equipment optimization is at the top of the list.
Is Your Dust Collector "Collecting Dust"?
Dust collection itself is not new. Your dust collector has been there for a while. In most cases, longer than you. The federal regulations that require them have been around since the 1970s. Your actual dust collector is, idiomatically, collecting dust.
The sheer number of plants required to have dust collection systems in place is huge:
Woodworking operations, sawmills, furniture manufacturing, and wood processing facilities are typically required to have dust collection systems in place.
If you produce certain chemicals, depending on the specific chemicals involved and the potential for emissions, your facility may need to have dust collection systems to comply with EPA regulations.
Many metalworking processes, such as welding, grinding, and cutting, can generate airborne particulate matter. This type of manufacturing facility may be subject to EPA regulations that require the installation of dust collection systems to control emissions and protect air quality.
Mining operations, including coal mining, mineral extraction, and quarrying, often generate significant amounts of dust. The EPA has regulations, such as the New Source Performance Standards (NSPS), that impose requirements on the control of dust emissions from mining activities.
Facilities involved in grain handling, such as grain elevators, mills, bakeries and food processing plants, often have regulations in place for controlling dust emissions. The EPA's Grain Handling Facilities National Emission Standard for Hazardous Air Pollutants (NESHAP) addresses particulate matter emissions from grain handling operations.
FPE Automation has experience with all of the above, plus pet food manufacturers, hospitals, and a manufacturer of roofing products, which you'll read more about below.
This is not intended to be an all-inclusive list. If you're not sure if you're required to have a dust collection system in your plant, check with the appropriate regulatory authority. However, this list does give an idea of how many businesses across the United States have been required to comply since the NESHAP guidelines were adopted a half-century ago. If you're reading this, you may be one of the hundreds of thousands of individuals somehow involved in managing a dust collection system.
Companies like ComEd and Ameren like what the raw data shows. PV technology from MAC Valves is provento significantly reduce energy consumption.
FPE Automation has also partnered with the energy providers in the region. Companies like ComEd and Ameren like what the raw data shows. In other words, this technology is proven to significantly reduce energy consumption.
Better Air Quality: A Technological Breakthrough
Dust collection is not new, and that's exactly the problem. Many dust collection systems have not changed significantly over the past 50 years. If equipment optimization tops the list of effective strategies to save energy, then why haven't more manufacturers looked to their obsolete methods of dust collection, as a way to reduce energy costs?
The answer is simple. Until recently, the technology remained relatively unchanged.
Dust collection engineering is finally catching up with the green initiative.
When cleaner is not better: this inefficient dust collection system is running, but collecting next to nothing. A nearly complete waste of energy.
The current generation of pulse valves (PV) from MAC Valves collects more airborne contaminants, using less energy. Best of all, their improved, patented design isn't susceptible to sticking, jamming or breaking down. Remember those hidden costs of improvement mentioned above? Replacing your pulse valves just once can eliminate the need for workers to perform ongoing emergency replacements. Not to mention the hazards of climbing up to access them.
A New Era of Green Energy for Dust-Collecting Manufacturing Plants
As with most new technology, if it's good, then word begins to spread.
FPE Automation's award-winning team. L to R: Scott Jokerst, Steve Carrera, Cody Schmelzle
A global manufacturer of roof shingles had recently retrofitted their Florida plant with new, better-performing pulse valves. Dust Collection expert Jonathan Moon from Adams had received an industry award for the upgrade.
An update in progress: replacing underperforming valves with MAC Valves. Photo courtesy of Doug Adams, used with permission.
That success story was passed on to their sister plant in Piedmont, Missouri. FPE Automation's Scott Jokerst, Solution Specialist, and Steve Carrera, Dust Collection Expert, stepped in to assist them in retrofitting that plant with new, better-performing pulse valves.
After testing and implementation at the facility in Piedmont, a detailed assessment took place. It was determined to be so successful that another location in Jonesburg, Missouri, wanted to duplicate it. The plant engineer worked with Cody Schmelzle and Steve Carrera. He informed FPE Automation that his corporation had an incentive for projects that helped the company save energy. FPE Automation and MAC Valves worked with the company to make certain that delivery aligned with his deadline.
As a result, on May 31, 2023, FPE Automation received an industry award from MAC Valves for their expertise and participation in two major installations. Mathew Neff, President & COO, and Joseph Richardson, VP of Sales for MAC Valves, made the announcement and congratulated the team.
Technology has finally caught up. In the area of dust collection, we are now able to reduce energy costs in a measurable way without hidden costs or other pitfalls. At the same time, we can reduce the level of airborne contaminants, enhance reliability and improve serviceability. All more efficiently than we could before.
Pulse valve upgrades continue to see record growth as the news becomes more widely shared. The global roofing company has continued its corporate initiative to reduce greenhouse gas emissions, and the individual plants see the MAC Pulse Valve as a great way to accomplish that.
One by one, companies are following suit; taking real steps toward protecting their employees, the environment, and our planet.
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