A new report released today by MHI and Deloitte finds that 55% of supply chain leaders are increasing their supply chain technology and innovation investments with 60% saying they are planning to spend over $1 million. Nineteen percent plan to spend over $10 million.

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Many new tower block development projects face a common challenge: how to install large, heavy pieces of equipment into the building’s energy centre, typically located in the basement. Specifying the optimal hoists is paramount to project success. Fortunately, the subcontractor supplying and installing the energy room’s plant for this particular project knew where to turn for a turnkey lifting solution: Hoist & Winch Ltd.

Hoist & Winch has extensive experience in all kinds of construction and industrial lifting applications. The company offers sales, installation, service, inspection, repair and hire services, with a special emphasis on project work. Supplying the optimal solution, with safety as the number one priority, is always the objective.

During the design phase, after formal tender and contract award, Hoist & Winch set about identifying the optimal solution by carefully assessing the specific lifting requirements. The project required the installation of hoists on both the upper and lower ground floor levels to ensure the successful lifting and transfer of large energy plant. It was clear from the outset that the solution would need to overcome the issue of very tight headroom clearances due to the size of the equipment.

After thoroughly considering all aspects of the project, Hoist & Winch Ltd was able to put forward its proposal, recommending two William Hacket low-headroom manual hoists, both with a hand-geared trolley. Offering a safe working load (SWL) of 2.5t each, the hoists provide 8m of lifting height and run on beam lengths of 8.5m and 7.0m.

Hoist & Winch duly submitted its design proposal, including drawings and structural calculations, for approval by engineers at the main contractor. Following approval, the company commenced manufacture before delivery to site.

During the installation phase, Hoist & Winch tested the installation anchor points to 1t before raising each beam into position using hand chain blocks. Elevating the beams to full height and clamping them hard against the concrete ceiling ready for drilling required the use of special lifting rigs. Once in position, the company proceeded with drilling operations and resin anchor installation for all ceiling anchor points after meticulously cleaning each hole with a special heavy-duty internal brush and suction pump. Following the specified resin curing time, Hoist & Winch tightened each anchor bolt to the required torque levels.

LOLER (Lifting Operations and Lifting Equipment Regulations) inspection of the lifting beams and manual chain hoist units was the final operation. This activity included dynamic load testing of both beam lengths with a 2.5t skid-mounted test load followed by 125% static proof load test in accordance with BS 2853 2011. As a point of note, following customer handover, the hoists were to remain in place for use by the on-site maintenance team.

“We provided the client with a comprehensive project records and documentation package upon completion of works, which is standard practice,” says Hoist & Winch Director Andy Allen. “We then went through the handover process to ensure total peace of mind for our client. At Hoist & Winch, our focus is on ensuring customers benefit from our exceptionally knowledgeable team who never fail to deliver on their promise of providing a detailed and proficient approach to every project.”

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Introducing Olis: Seeing is Believing

Olis Robotics offers a unique approach to robot troubleshooting. Unlike traditional methods, which rely on log files and error codes that can be cryptic for non-experts, Olis leverages video alongside data. The system captures video recordings whenever an issue arises, synchronized with corresponding log files from all connected robot controllers, including the recently integrated Rockwell Allen-Bradley PLCs. This comprehensive data allows users to not only see the problem but also understand the context in which it occurred.

Unlocking New Possibilities with PLC Integration

The integration with Rockwell Allen-Bradley PLCs represents a significant leap forward for Olis. Previously limited to individual robots, the system can now monitor entire automation cells encompassing multiple robots and PLCs. This opens doors for applications in various industries, including the automotive sector that wasn’t previously well-served by Olis’ technology.

Demystifying Data: Actionable Insights at Your Fingertips

Olis goes beyond simply capturing data. It empowers users to extract actionable insights. The system allows for historical data analysis, enabling proactive maintenance by identifying trends that could lead to future problems. Users can configure alerts based on specific parameters, receiving notifications when cycle times increase unexpectedly or consumable resources start to dwindle.

Remote Expertise: A Boon for All

One of the most significant advantages of Olis lies in its ability to facilitate remote troubleshooting. The system allows users to access critical data and live video feeds from anywhere with an internet connection. This is particularly valuable for small and medium-sized businesses (SMBs) that may lack in-house robot expertise. Olis enables them to connect with remote experts who can diagnose problems and guide them through solutions, eliminating the need for costly on-site visits.

Universal Applicability: From First-Timers to High-Stakes Operations

Olis caters to a broad spectrum of users. For first-time robot adopters, the system provides invaluable training wheels. When unexpected issues arise, they can receive remote support, helping them understand the problem and troubleshoot effectively. This fosters a learning environment where users gain confidence in operating their robots.

On the other end of the spectrum, Olis caters to high-stakes operations with significant downtime costs. The system’s ability to synchronize and present data from various sources enables rapid decision-making, minimizing downtime and safeguarding production schedules.

A Perfect Fit for Modern Warehousing and Manufacturing

The rise of lights-out manufacturing and automation in warehouses underscores the need for reliable remote monitoring solutions. Olis perfectly aligns with this trend. Businesses can rest assured that their robots are functioning optimally, even during off-hours. Early detection of problems prevents production delays and ensures on-time deliveries.

Hedging Against Uncertainty: Building Expertise Resilience

The high turnover rate in the robotics industry poses a challenge for automation users. Olis offers a solution by providing access to a network of remote experts. Even if a company lacks an in-house robot expert, they can still leverage Olis to connect with qualified professionals when needed.

Beyond the Interview: Resources for the Curious

Interested in learning more about Olis Robotics? There are numerous resources are readily available.

• Connect with Fredrik Ryden on LinkedIn: Search for “Fredrik Ryden CEO of Olis Robotics” to connect directly with Fredrik.
• Visit the Olis Robotics website: Explore OlisRobotics.com to find detailed information about the system, its capabilities, and case studies.
• Explore the Olis YouTube channel: Access the Olis YouTube channel directly from the website to watch informative videos showcasing the system in action.

Conclusion

Olis Robotics is revolutionizing the way businesses approach robot troubleshooting and maintenance. By leveraging video-based diagnostics and facilitating remote support, Olis empowers users of all sizes to optimize their automation processes, unlock efficiencies, and achieve their production goals. As the industry continues to embrace automation, Olis is poised to play a pivotal role in ensuring its smooth and successful implementation.

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The new mobile app provides an interactive and engaging experience for customers that can only be found at EXAIR. App users can quickly browse and place products directly into their environment to ensure a perfect fit into their application. The app expedites the solution finding process by allowing users to select their specific sizes and performance requirements, place a 3D version of the product in their actual workspace, and navigate to a page to purchase, all from their mobile device. The app also includes a library of conversion calculators to further assist with quick problem solving and computations on-the-go.

The EXAIR AR (Augmented Reality) Mobile App gives customers a breadth of the company’s products at their fingertips and allows for easy selection of process-improving solutions without ever having to leave their facility or production line. The app is the next step in the company’s continued efforts to offer the most advanced level of value for our customers. In addition, EXAIR.com has a large Knowledge Base that offers many other resources to help customers find and select the right solution for their application. Browse through product videos, performance data, CAD files, installation and maintenance guides, air savings calculators, case studies, slide presentations and an extensive Application Database including over one-thousand solutions to learn how EXAIR Intelligent Compressed Air® products can improve your processes. Search for, and download the EXAIR AR App by visiting the Apple or Google Play stores today. https://exair.co/153-mob-ar

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Understanding ASRS Technology

Automated Storage and Retrieval Systems are sophisticated, high-density warehouse solutions designed to automate the handling of inventory. These systems consist of several key components, including storage racks, retrieval machines (such as cranes or shuttles), and a warehouse control system. There are various types of ASRS, each suited to different warehouse requirements and product sizes:

• Unit-Load ASRS: Designed for handling large items or pallet-sized loads.
• Mini-Load ASRS: Suitable for smaller items, typically stored in totes or bins.
• Micro-Load ASRS: Used for handling very small items, often integrated into parts-picking operations.
• Carousel-Based ASRS: Utilizes rotating shelves to deliver items to a picking station.

The integration of advanced robotics, sensors, and control software allows these systems to operate with minimal human intervention, ensuring precision and reliability in inventory handling.

Role of ASRS in JIT Inventory Management

The implementation of ASRS is crucial for the effective execution of JIT inventory management in manufacturing warehouses. By automating the storage and retrieval processes, ASRS ensures that materials are available exactly when needed, thus synchronizing seamlessly with production schedules. This real-time capability eliminates delays and reduces the necessity for large inventory buffers, which is a fundamental aspect of JIT principles. ASRS can swiftly and accurately store incoming materials and retrieve them for production, maintaining a continuous flow of inventory that supports ongoing manufacturing processes.

Benefits of Using ASRS for JIT Management

The adoption of ASRS within JIT inventory management brings several substantial benefits:

• Increased Efficiency and Reduced Lead Times: ASRS systems significantly speed up storage and retrieval processes, thereby reducing lead times and ensuring materials are available for production without delay.
• Minimization of Inventory Holding Costs: By closely aligning inventory levels with production needs, ASRS helps minimize costs associated with holding excess inventory, such as storage costs, insurance, and obsolescence.
• Enhanced Accuracy in Inventory Tracking and Movement: ASRS provides precise tracking of inventory locations and movements, reducing errors and ensuring the right materials are available at the right time.
• Flexibility in Adapting to Changing Production Demands: ASRS can be easily reconfigured to adapt to changing production schedules and inventory requirements, providing the flexibility needed in dynamic manufacturing environments.
• Reduction in Labor Costs and Human Error: Automation reduces reliance on manual labor for storage and retrieval tasks, lowering labor costs and minimizing the risk of human errors.

Implementation Challenges

Despite its advantages, implementing ASRS in JIT inventory management does present certain challenges:

• High Initial Investment and Cost Considerations: The initial cost of purchasing and installing ASRS can be substantial, requiring careful financial planning and justification.
• Integration with Existing Warehouse Management and ERP Systems: Successful implementation requires seamless integration with existing warehouse management systems (WMS) and enterprise resource planning (ERP) systems to ensure smooth operations.
• Training and Adaptation of Workforce: Employees need to be trained to work with the new automated systems, which can involve a learning curve and adaptation period.
• Maintenance and Operational Downtime: Regular maintenance is crucial to keep ASRS running smoothly, and any downtime can disrupt the JIT inventory flow, impacting production.

Technological Innovations Enhancing ASRS

Ongoing technological advancements continue to enhance the capabilities of ASRS, making them even more valuable for JIT inventory management:

• Advances in Robotics and Automation: Improvements in robotic technology and automation have increased the speed, precision, and reliability of ASRS, enabling faster and more accurate inventory handling.
• Integration with IoT and Real-Time Data Analytics: The integration of Internet of Things (IoT) devices and real-time data analytics allows for better monitoring, control, and optimization of ASRS operations, improving efficiency and reducing downtime.
• Development of More Robust and Scalable Systems: New ASRS designs are more robust and scalable, allowing them to handle a wider range of products and adapt to growing warehouse needs.
• Use of AI and Machine Learning for Predictive Maintenance and Optimization: AI and machine learning algorithms are being used to predict maintenance needs and optimize ASRS performance, reducing downtime and extending the lifespan of the systems.

Case Studies of ASRS in JIT Inventory Management

In a global marketplace where efficiency and precision are paramount, many manufacturing companies have successfully implemented ASRS to enhance their JIT inventory management processes. While we won’t dive into specific case studies, it’s worth noting that companies across various sectors, including automotive, electronics, and consumer goods, have reported significant improvements in operational efficiency, cost savings, and product quality through the integration of ASRS. These real-world applications underscore the transformative potential of ASRS in modern warehouse and supply chain management.

Future Trends and Outlook

The future of ASRS in JIT inventory management looks promising, with several trends and innovations on the horizon:

• Emerging Technologies in ASRS Development: Continued advancements in robotics, AI, and IoT are expected to further enhance the capabilities and efficiency of ASRS, making them even more integral to JIT inventory management.
• Potential for Increased Adoption in Various Industries: As the benefits of ASRS become more widely recognized, their adoption is likely to increase across a variety of industries, from manufacturing to retail and logistics.
• Impact of ASRS on the Future of Warehouse and Supply Chain Management: ASRS is set to play a key role in the evolution of warehouse and supply chain management, driving greater efficiency, accuracy, and responsiveness in inventory management.
• Development of Modular and Flexible ASRS Solutions: Future ASRS designs may focus on modularity and flexibility, allowing for easier customization and scalability to meet the specific needs of different warehouses and inventory types.
• Integration with Advanced Data Analytics and AI: The integration of advanced data analytics and AI technologies will enable more sophisticated inventory management strategies, including predictive analytics for demand forecasting and real-time optimization of storage and retrieval operations.

Conclusion

The integration of Automated Storage and Retrieval Systems (ASRS) with Just-in-Time (JIT) inventory management offers a powerful solution for manufacturing warehouses. By automating the storage and retrieval processes, ASRS ensures timely, accurate, and efficient inventory handling, aligning perfectly with JIT principles. Despite the challenges involved in implementation, the benefits of increased efficiency, reduced costs, enhanced accuracy, and greater flexibility make ASRS an invaluable tool for modern warehouse and supply chain management. As technological advancements continue to enhance the capabilities of ASRS, their role in JIT inventory management is set to grow, driving further improvements in operational efficiency and productivity.

The evolving landscape of warehouse automation, bolstered by innovations in robotics, AI, and IoT, promises a future where ASRS not only supports but revolutionizes the principles of JIT inventory management. As industries continue to seek greater efficiency and cost-effectiveness, the adoption of ASRS will likely become more widespread, heralding a new era of precision and agility in inventory management. By embracing these technologies, manufacturing warehouses can achieve a competitive edge, ensuring they are well-positioned to meet the demands of a fast-paced, dynamic market.

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Kardex solutions offer manufacturers efficiency, flexibility and short training times

Visitors to stand #4681 at Automate 2024 saw FulfillX in action, with demonstrations of how it can createuser-friendly, highly-configurable AutoStore systems. FulfillX optimizes picking and packing, while also streamlining putaway and other inventory processes. It provides a real-time overview of the whole operation in a simple window. Enhancements can be rapidly deployed by Kardex’s dedicated AutoStore support team and digital twins enhance planning and commissioning.

As well as promoting the benefits of FulfillX, Kardex’s booth used digital tools and augmented reality to bring to life the Kardex Intuitive Picking Assistant and its range of smart intralogistics solutions. Kardex’s Intuitive Picking Assistant solution is suitable for a wide range of industrial manufacturing applications, including spare parts picking, visual direction, and kitting. It uses digital tools and augmented reality to enhance picking processes by responding to movements and projecting relevant picking information directly onto the surface of the access opening. The Intuitive Pick Assistant is compatible with both and AutoStore ports to facilitate accurate, ergonomic picking, and can be tailored to specific customer requirements. In addition, it can be used to direct operators through kitting processes.

As US manufacturers increasingly turn to warehouse automation technology, AutoStore empowered by Kardex FulfillX provides them with the opportunity to slash their facility footprint, reduce workload, manage spikes in demand, and address labor and skills shortages.

Commenting on Kardex’s appearance at Automate 2024, Mitch Hayes, President of Kardex Solutions AutoStore, said, “Automate offered the ideal opportunity to introduce US manufacturers to AutoStore empowered by Kardex FulfillX. FulfillX represents the next evolution of ASRS technology. At Kardex we are committed to pushing the boundaries of what is possible with intralogistics automation. Our advanced software solutions provide manufacturers with the flexible, convenient and efficient capabilities they need to meet industry challenges now and in the future.”

Real-world case studies

MAHLE

As a leading global parts and solutions provider to the Independent Aftermarket, MAHLE Aftermarket saw a shift in customer order profiles from larger pallet orders to smaller package orders in higher frequency. This resulted in an increasing number of shipping points per customer and shipping smaller quantities to more locations.

To accommodate this shift, MAHLE Aftermarket implemented an AutoStore system from Kardex in their Olive Branch, MS location to automate small parts handling. Stay tuned for the official release of the MAHLE case study in mid-May 2024.

Anyseals

One company benefiting from AutoStore empowered by Kardex is Anyseals, a global wholesale sealing supplier. Anyseals provides their distribution customers with services including just in time delivery, bar coding, kitting and custom labeling. The company was moving from a completely manual to an automated operation and implementing a new WMS at its main US facility in Ohio. They turned to Kardex for a space-efficient, flexible solution to increase efficiency in small parts handling and facilitate growth.

The Anyseals AutoStore system went live in October 2023 and Anyseals described working with Kardex as “a great experience”, with employees happy with how the technology assists them with their work, 100% uptime at the facility and average picking time reduced from up to 15 minutes per pick to seconds, with substantial time saved on putaway as well. Rush orders are prioritized to ship on time and Anyseals is still learning what is possible with Kardex and AutoStore to enhance its processes further.

“The AutoStore solution will enable us to continue our strong growth trajectory and will enhance our ability to meet and exceed the high level of fulfilment execution for our customers”, says Toby Rose, COO at Anyseals USA.

About Kardex

Kardex is a global industry partner for intralogistics solutions and a leading supplier of automated storage solutions and material handling systems. The group consists mainly of two entrepreneurially managed divisions, Kardex Remstar and Kardex Mlog. Kardex is also a global AutoStore partner.

Kardex Remstar develops, produces, and maintains dynamic storage and retrieval systems and Kardex Mlog offers integrated materials handling systems and automated high-bay warehouses.

The two divisions are partners for their customers over the entire life cycle of a product or solution. This begins with the assessment of customer requirements and continues through planning, realization, and maintenance of customer-specific systems. It ensures a high level of availability combined with low total cost of ownership and operation. Approximately 2’100 employees in over 30 countries work for Kardex. Kardex Holding AG is listed on the Swiss SIX Stock Exchange since 1989.

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The new digital catalog offers a great number of easy-to-use tools to make finding a specific product easier than ever before. Users can quickly navigate to any product or section by clicking the tabs in the table of contents, searching the product name or model number. Readers will be taken directly to the page of their choice where they can scan specifications, models, applications and more. All catalog products offer clickable links that navigate the customer directly to EXAIR.com where they can gather more info on their solution or make a purchase. In addition, the digital catalog offers the ability to download PDF versions of any page, the ability to add personal notes on products they may be interested in, as well as clickable videos to be watched directly from the page.

EXAIR products are designed to conserve compressed air and increase personnel safety in the process. Detailed technical explanations, performance data, application photos and dimensional drawings are provided for each product to paint a full picture of what each solution offers. This adds to a long list of digital assets EXAIR makes readily available to customers, like Augmented Reality, 3D models, case studies, and more. Visit EXAIR.com to take advantage of these valuable resources and try the new digital catalog today.

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Mantle, the leader in metal 3D printing technology for toolmaking, today revealed new customers and several new case studies that illustrate how customers are automating their toolmaking with Mantle technology.

Mantle’s precision metal 3D printing technology is revolutionizing tooling component production by reducing the time and cost to produce high-quality tools, molds, and dies. Mantle’s technology uniquely meets the accuracy, surface finish, and tool steel property requirements of toolmaking while enabling unique tooling geometries and reducing skilled labor requirements.

Pushing the Boundaries in Medical Device Tooling
Westminster Tool, a comprehensive injection mold builder with a specialization in class 101 medical device tooling, acquired the inaugural shipment of a Mantle 3D printer in June 2022. Since then, the company has consistently identified new applications and tested the flexibility of what can be achieved with Mantle’s technology.

Westminster Tool recently partnered with a prominent medical device manufacturer to print a complex set of mold inserts so the OEM could quickly mold production-representative plastic parts to validate the material. With Mantle, Westminster Tool produced the steel mold inserts in just four weeks. Westminster Tool estimated it would have taken eight weeks with traditional manufacturing to build the same set of inserts, thereby allowing its customer to accelerate its product development process. The printed tools required only minor finishing and reduced labor and machining time by more than 110 hours. The H13 inserts had more than 40 swipe-by shutoff conditions and contoured parting lines, and demonstrated the ability of Mantle’s technology to be used for demanding, complex inserts that would typically require extensive time from toolmakers to produce.

Expansion with New Customers
Continuing the momentum in the field of medical device manufacturing, Mantle also revealed today that Spectrum Plastics Group, a DuPont Business and medical contract manufacturer, will be implementing the company’s metal 3D printing technology within its facilities.

Mantle also announced that Heyco Products, a Penn Engineering company specializing in wire protection and termination for a range of industries, has implemented Mantle’s metal 3D printing technology into its toolmaking workflows. As a leading manufacturer of thousands of complex plastic and metal components, high-quality tooling is critical to Heyco’s success.

“At Heyco, we pride ourselves on taking products from design through to volume production, which includes in-house prototype and production tooling. Mantle allows us to increase our toolmaking capacity and project speed by automating a portion of our toolmaking process, helping to maximize our skilled resources.” – Danny Anthony, Vice President of Operations at Heyco Products

Easing Labor Scarcity of Tool Makers 
Across manufacturing as a whole, especially in toolmaking, labor scarcity has emerged as a predominant challenge, hindering manufacturers’ efficiency and capacity to build tooling.

Recognizing the growing scarcity of skilled toolmakers, General Pattern, an injection molder with in-house tooling services and more than 100 years of experience, is addressing the labor issue by introducing Mantle’s 3D printer to automate its toolmaking processes and bolster capacity. The investment in Mantle underscores the company’s dedication to cutting-edge technologies and highlights its potential to alleviate the industry’s labor shortage. General Pattern anticipates the benefits of this investment to include heightened efficiency, decreased reliance on specialized labor, and improved customer service through faster and more efficient operations.

“Introducing Mantle into our operations has elevated our approach to toolmaking. With the simple press of a button, we can now effortlessly create tools, which completely changes our ability to tackle labor challenges and enhances our capacity to better serve our customers. Recently with a slide for a transportation trim component, for example, we skipped the finishing process entirely. Instead, we printed it, assembled it into the mold, and immediately began molding parts. This not only saved us the 40 hours of traditional toolmaker time typically required to build this slide, but also freed up my team to focus on other critical projects.” – Denny Reiland, CEO at General Pattern

“Mantle’s technology remains a game-changer in the toolmaking industry, consistently driving reductions in lead times and costs while addressing labor shortages. The latest deployments, with Spectrum Plastics Group, Heyco, and General Pattern, coupled with the ongoing success of our existing customer, Westminster Tool, underscore the growing adoption and effectiveness of our technology.” – Ted Sorom, CEO and Co-founder of Mantle

About Mantle

Mantle accelerates product development by simplifying how mold tool components are made. Mantle’s TrueShape metal 3D printing technology delivers the accuracy, surface finish, and tool steel properties required for demanding tooling applications. Tools made with Mantle’s technology have produced millions of parts while reducing tooling lead times and costs. Mantle is headquartered in San Francisco, California.

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As General Manager at the Oakland Athletics, Beane used data-driven methodology to turn a low-payroll team into one of the most successful organizations in baseball. He demonstrated how, through innovative leadership and thoughtful use of undervalued assets, a smaller organization can outdo its bigger, higher-profile rivals. Now, Beane explains how his methods can apply to almost any industry.

“Many of automation’s most exciting applications rely on thoughtful use of data,” said Jeff Burnstein, president of the Association for Advancing Automation (A3), “and Billy Beane’s accomplishments with the Athletics prove just how powerful data can be in the right hands, no matter the application. We can’t wait to hear his thoughts on how organizations of every size can leverage their assets in the best ways possible.”

Automate is happening May 6–9 in Chicago, Illinois. Attendance is free for anyone who works with or is interested in, automation. Every year, the show draws exhibitors and attendees from all around the world—and with over 365,000 square feet of show floor, 800+ exhibitors, 200 speakers and 30,000 registrants, this year is no exception. Attendees will make new professional connections and see the latest solutions in cutting-edge robotics, vision, artificial intelligence, motion control and related automation technologies.

In conjunction with the free show, the paid Automate Conference will feature 200+ accomplished industry professionals leading classroom-style sessions. Those looking to sharpen their skills or deepen their automation knowledge should sign up for these educational conference sessions to get practical solutions, discover the latest innovations or learn from real-world case studies. Conference attendees can also take advantage of Certified Vision Professional courses in basic and advanced tracks and Certified Motion Control Professional – Basic courses culminating in an exam to secure professional certification (exam fees are separate).

About The Association for Advancing Automation (A3)

The Association for Advancing Automation (A3) is the leading global advocate for the benefits of automating. A3 promotes automation technologies and ideas that transform the way business is done. Members of A3 represent more than 1,200 automation manufacturers, component suppliers, system integrators, end users, academic institutions, research groups and consulting firms that drive automation forward worldwide.

A3 hosts a number of industry-leading events, including the A3 Business Forum (January 15–17, 2024, Orlando, FL); Automate (May 6–9, 2024 in Chicago, IL); the International Robot Safety Conference (October 1–3, 2024, Cincinnati, OH); and the Autonomous Mobile Robots & Logistics Conference (October 8–10, 2024, Memphis, TN).

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Since they aid in fostering a culture of safety awareness, toolbox talks play a pivotal role in preventing accidents and ensuring a secure (and compliant) workplace.

This article delves into how these talks specifically tackle the multifaceted challenges of safety and compliance in the manufacturing maintenance realm. The goal is to help understand how toolbox talks not only raise awareness but also actively contribute to mitigating risks and adhering to stringent regulatory standards, thereby promoting a safer and more compliant workplace.

Toolbox Talks in Maintenance Safety

In manufacturing maintenance, workers are frequently exposed to a range of hazards. Electrical risks — including electrocution, short circuits, and sparks leading to fires — involve exposure to live wires or faulty electrical equipment, posing significant dangers.

Machinery malfunctions can lead to catastrophic accidents, especially with heavy or high-speed equipment. These include breakdowns, unexpected start-ups, or equipment failures causing injuries. Ergonomic injuries, often overlooked, arise from repetitive tasks or improper handling of equipment, lifting heavy items, or poor workstation design, and are known for leading to long-term musculoskeletal issues.

Some other, frequently occurring risks include:

• Chemical exposures: contact with hazardous substances causing health risks.
• Falls and slips: due to wet floors, uneven surfaces, or working from heights.
• Noise exposure: this leads to hearing loss from prolonged exposure to loud machinery.

Toolbox talks are instrumental in cultivating a robust safety culture, emphasizing preventive measures and proactive safety management. They enable teams to identify potential hazards and discuss practical solutions, such as proper use of safety gear or machinery operation protocols.

For instance, a toolbox talk could focus on the correct way to handle a new high-speed cutting machine, addressing both operational procedures and safety precautions, thereby reducing the risk of accidents and reinforcing a culture of safety vigilance.

Compliance Challenges in Manufacturing Maintenance

Compliance in manufacturing maintenance is a complex landscape, dominated by stringent standards like those set by OSHA and various local safety regulations. These standards cover a broad spectrum of issues, from equipment safety to employee training requirements.

For example, OSHA’s guidelines on hazardous energy control (lockout/tagout procedures) are crucial for maintenance personnel to understand and implement to avoid severe accidents. But, as stated earlier, the regulatory landscape includes an array of considerations:

• OSHA standards: meeting guidelines on hazardous energy control, machine guarding, and PPE usage.
• Local safety regulations: adhering to specific local or state safety and environmental standards.
• Environmental regulations: compliance with waste disposal and air quality standards.
• Fire safety regulations: ensuring adherence to fire safety protocols and equipment maintenance.
• Emergency response preparedness: preparing for accidents, natural disasters, or other emergencies.
• Training and certification requirements: ensuring all workers are appropriately trained and certified.

Toolbox talks are an effective platform to keep staff updated on evolving compliance standards and best practices in maintenance safety. Regularly including topics on recent regulatory updates or introducing new safety procedures ensures that all team members are informed and prepared.

One such talk could focus on new amendments to machine guarding regulations, explaining the changes and how they impact daily maintenance activities, ensuring that the team not only complies with the law but also adopts best safety practices.

Another iteration of a toolbox talk could focus on the latest updates in hazardous chemical handling and storage regulations. This session could detail how new labeling requirements and safety data sheet formats must be integrated into the maintenance team’s routines.

Discussing these changes helps ensure that team members are aware of the proper procedures for handling, storing, and disposing of chemicals, thereby not only complying with the updated regulations but also significantly enhancing workplace safety and reducing the risk of chemical-related incidents.

Implementing Effective Toolbox Talks

Effective toolbox talks are tailored to address specific safety and compliance needs unique to each maintenance team. This involves customizing content to reflect the particular machinery, machinery maintenance, other processes, and risks inherent in the team’s daily operations.

A team working with advanced robotic assembly lines would benefit from talks that focus on the safe interaction with automation and emergency protocols specific to such equipment. That’s why you must ensure topics are directly relevant to the team’s daily tasks and potential risks, and regularly update content to reflect changes in equipment, procedures, or regulations.

Use interactive methods like Q&A sessions, hands-on demonstrations, or group discussions to maintain engagement — incorporating real-life incident analyses can make sessions more relatable.

One of the many must-haves with toolbox talks is consistency — hold talks regularly, but avoid over-scheduling to maintain their effectiveness and perceived value. Also, try to actively seek feedback from attendees and use it to improve future sessions. This could involve modifying the format, content, or delivery based on employee suggestions.

To engage maintenance personnel effectively, toolbox talks should incorporate interactive elements like hands-on demonstrations or analysis of real-world incident case studies. This approach keeps the sessions engaging and provides practical, tangible learning experiences.

One example — a hands-on demonstration of the correct procedure to shut down a malfunctioning conveyor belt effectively reinforces the learning and ensures better retention and application of safety protocols.

Measuring Toolbox Talk Effectiveness in Maintenance

Key Performance Indicators (KPIs) are essential to measure the impact of toolbox talks on safety in maintenance operations. These metrics provide quantitative data to assess whether these talks are effectively reducing accidents and improving adherence to safety protocols.

These KPIs include:

• Incident rates: frequency and severity of workplace accidents and injuries.
• Near-miss reports: tracking incidents that could have led to accidents but were narrowly avoided.
• Compliance audit results: regular checks on adherence to safety and regulatory standards.
• Employee safety training completion: rate of employees completing mandatory safety training.
• Employee feedback and engagement: surveys and feedback mechanisms gauging employee participation and understanding.
• Toolbox talk attendance records: monitoring how many workers are actively participating in these talks.

A noticeable decrease in incident rates post-implementation would indicate a positive impact on workplace safety.

Obtaining and utilizing feedback from maintenance staff is crucial for the continuous improvement of toolbox talks. Methods like post-talk surveys, interactive feedback sessions, and observational feedback provide direct insight into the effectiveness of the talks.

Regular review meetings to discuss feedback results and observations can lead to adjustments in the talks, ensuring they remain relevant, engaging, and effective in addressing the evolving needs of the maintenance team.

The Final Piece in Your Safety and Compliance Puzzle

Toolbox talks are indispensable in enhancing safety and compliance in the manufacturing maintenance sector. Their role in fostering a culture of safety awareness, educating personnel on best practices, and ensuring adherence to regulatory standards cannot be overstated.

They serve as a critical component in the pursuit of a safer, more efficient, and compliant maintenance environment.

Maintenance managers and team leaders are encouraged to either adopt or refine their approach to toolbox talks, focusing on the long-term benefits they bring in terms of safety and compliance.

Continuously evolving these talks to meet the specific needs of their teams — and staying abreast of the latest safety standards and technologies — can significantly enhance the overall safety and efficiency of their maintenance operations.

By: Sanjay Murthi

About the Author

Sanjay Murthi works for SMGlobal. SMGlobal’s FastMaint CMMS software is a powerful & easy-to-use maintenance management software program used by customers worldwide to manage facility and equipment maintenance.

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