Smart Automation: Overcoming Labor Shortages
Introduction: The Rising Challenge of Labor Shortages
Across the globe in both processing and manufacturing sectors, businesses are facing the challenges of finding and keeping a skilled workforce to meet their production demands. Many factors could be contributing to this, such as an aging workforce or even just a lack of interest or ambition in factory jobs. Regardless, the pool of skilled operators and technicians is getting smaller and smaller, putting pressure on production teams.
What Is Smart Automation?
Smart automation is a step up from using traditional machinery due to its integration of sensors, data analytics, and intelligent controls to optimize operations with minimal human intervention. Being defined as “fully-integrated, collaborative manufacturing systems that respond in real time to meet changing demands and conditions in the factory, in the supply network, and in customer needs”, by the NIST (National Institute of Standards and Technology) This automation allows for self-correction and improved efficiency. When compared to traditional automation, which just sees machines perform fixed tasks at fixed intervals, without the ability to adapt to any changes or errors. This is an improvement that cannot be ignored.
How Smart Automation Addresses Labor Shortfalls
Smart Automation can help to reduce any labor shortfalls your plant may have, thanks to the automation of repetitive, labor intensive and potentially dangerous tasks such as material transportation, manufacturers and processors can afford to do more work, with fewer workers at their disposal. Other operations like extrusion can now also be automated, reducing the need for an operator to be constantly overseeing the process. All of this automation will also help to reduce the risk of human error, reducing material and operational costs.
Industry Example: Automation in Action
One such example of automation in action is our work with Epsilyte. Epsilyte aimed to improve its material mixing process by eliminating manual handling, reducing material separation, enhancing accuracy, and increasing overall efficiency. TSM provided a solution that was able to achieve all of these goals.
The project included:
Opti-Mix 1500 Blenders for precise mixing
A central vacuum system to automate material transport
A bag break station to facilitate material loading
External silos for efficient material storage
A railcar unloading system for high throughput material transfer
The installation of TSM’s turnkey solution resulted in significant improvements in Epsilyte’s operation:
Increased Efficiency: The elimination of manual handling and reduced material separation led to greater process efficiency and accuracy.
Enhanced Speed: The new vacuum system enabled rapid material transfer from storage silos and surge bins to the Opti-Mix 1500 Blenders, achieving a rate of up to 3,300 lbs./hr. and ensuring a smooth operation across their production lines.
Improved Safety: By automating material handling, the system reduced workplace safety hazards associated with manual labor.
System Integration: The seamless integration of blenders, the vacuum system, silos, and railcar unloading resulted in a fully automated, efficient material handling process.
Overcoming Adoption Barriers
Some companies may hesitate to invest in smart automation for many reasons, such as potential cost, potential disruption to workflows or even assumed difficulty in adjusting to the new systems. These concerns are put to rest however, thanks to our smart systems being designed to retrofit into existing production lines with minimal downtime. With support from us and our partners, modular implementation plans, and built-in training tools we will help ease the transition and boost team confidence.
A Smarter Path Forward
In the face of persistent labor shortages, smart automation isn’t just a solution to the problem, it’s a strategic advantage that will help you future-proof your factory’s operations.
Are you ready to future-proof your production?
Discover how TSM’s smart automation solutions can help you overcome labor challenges, reduce waste, and maximize throughput.
Contact our team today to schedule a consultation or request a tailored solution for your process.