Reliability Engineers Need the Best Tools to Ensure Safe and Efficient Automated Warehouses and Factories
TinMan Systems
Smart Sensor Systems Software and Hardware for Industrial IoT Reliability Maintenance
Automation in warehouses and factories is becoming increasingly common in today’s fast-paced business environment. These facilities are now equipped with a wide range of automated systems, including sophisticated conveyor systems, robots, and automated storage and retrieval systems (AS/RS) . The length of conveyor systems can vary depending on the size of the facility and the number of products being transported. For example, Amazon’s largest fulfillment center in the United States has a conveyor system that is over 14 miles long. Bigger ones are coming. The number of robots and other automated systems can also vary depending on the size of the facility and the specific needs of the business. For instance, Amazon has over 200,000 mobile robots operating in its warehouses worldwide .
Higher Costs of Downtime
According to Forbes, unplanned downtime costs industrial manufacturers as much as $50 billion a year . The cost of an hour’s downtime in an automotive plant is now more than $2 million – up from $1.3 million in 2019–20 . Effective predictive and preventative maintenance on conveyor systems is crucial for sustaining maximum uptime. Unplanned downtime can lead to costly repairs, lost productivity, and missed deadlines.
Higher Worker Turnover Rate
According to the Bureau of Labor Statistics, the annual turnover rate for warehouse and storage workers was a staggering 49% in 2022 . The separation rate for the manufacturing industry was 44.3% in 2020, with a 59.5% separation rate for the warehousing industry . These high turnover rates can lead to increased costs and reduced productivity.
Increased Hazards
In addition to high turnover rates, warehouses and factories can also be hazardous work environments. In 2020, there were 24,900 incidents where warehousing and storage workers were injured and had to take time off work to recover . Most of these injuries (12,220) involved sprains, strains, or tears, and approximately 1,500 cases were fractures . It’s important to ensure that workers are properly trained and equipped to handle the demands of working in an automated warehouse or factory.
领英推荐
Reliability Engineers Play Critical Role
The rise of warehouse automation has led to faster package delivery and increased throughput, which in turn has put new demands on reliability engineers to keep the automated warehouses and factories moving smoothly and efficiently. By providing reliability engineers with the best tools, such as innovative preventative maintenance sensor systems and predictive maintenance solutions that provide continuous monitoring of critical industrial and machinery assets, they can do their job more efficiently and safely. This helps reduce downtime, increase productivity, and improve worker safety.
TinMan Systems’ predictive and preventative maintenance solutions and technology help reliability engineers do a better, more efficient job that is also safer. By continuously monitoring conveyor systems and detecting early warning signs of potential failures, TinMan Systems’ Cascades Smart Wireless Multi-Sensor System for continuous monitoring of critical moving components of conveyors and sorters can help reduce unplanned downtime . This is crucial for sustaining maximum uptime, as unplanned downtime can lead to costly repairs, lost productivity, and missed deadlines. By addressing maintenance needs during scheduled downtimes, industries can save significant costs over time.
TinMan Systems’ preventative maintenance solutions can also help reduce the risk of workplace injuries. Our Mobile Conveyor Inspection System (MCIS) is an Autonomous Multi-Sensor Diagnostic Inspection Device for Conveyor Systems. It is equipped with an integrated set of distance sensors, accelerometer, gyrometer, magnetometer, 3 HD video cameras, thermal video camera, microphone for sound recording, 3-direction lights, and optionally, an RFID location and positioning system. By using MCIS, reliability engineers can quickly and easily inspect conveyor systems for damage or wear and tear. This helps them to identify and address issues before they become major problems, thereby improving worker safety. The attached Cascades Smart Wireless Sensors provide continuous monitoring of critical components of the conveyor systems in areas and at times that are not possible for the engineer to measure safely or at all.
Reliability engineers are essential to the success of automated warehouses and factories. They play a critical role in ensuring that these facilities operate smoothly and efficiently. By leveraging innovative systems and technologies, reliability engineers can help reduce downtime, increase productivity, and improve worker safety.
Contact TinMan Systems today to learn more or schedule free onsite demonstrations of these solutions. Email us at [email protected]
References used in this article: