IEN: How can this sector meet rising demand for greater automation and flexibility?
Thouvenot: Manufacturers can meet these demands by providing a higher level of integration between their information systems and factory floor automation. Final assembly of manufactured products can be postponed until actual orders are received. Components can be manufactured and held in buffer storage systems at minimal inventory levels. Then, as orders are received, the order information can be downloaded to the factory floor material handling system (MHS). The MHS can then automatically select the components required to meet the order and convey those components, along with the packaging materials for the product, to a final assembly and packaging line. Inventories are kept to a minimum and the time from receipt of an order to shipment is dramatically reduced.
IEN: What innovations are in store for users of equipment, systems, components, materials, and software?
Thouvenot: The major innovation talked about today is RFID (Radio Frequency Identification). RFID will allow the automation to be accomplished more accurately and at higher speeds than current bar code technology.
The other innovation that continues to evolve is the integration between the information flow processes and the material flow processes. As computer technology and PLC technology continue to evolve, it will become easier to translate order requirements into the real time factory floor transactions required to fulfill the orders.
IEN: How can downtime issues be resolved? Through RCM, web-based monitoring, embedded maintenance? Other solutions?
Thouvenot: Downtime is a major issue for all manufacturers. Some manufacturers are minimizing downtime by putting in redundant systems for critical parts of the manufacturing operation. Others have committed to standardization of the equipment, equipment components, controls formats, programming formats, etc, to make it easier for their personnel to maintain and troubleshoot their systems.
Preventive and predictive maintenance is also a critical issue. Manufacturers are providing more formal training for their maintenance and operations personnel. Manufacturers are also asking their equipment suppliers to provide equipment audits and service engineers to ensure that they maximize the uptime on their equipment.
IEN: What progress do you see in meeting safety and security goals?
Thouvenot: Safety and security continues to improve as equipment suppliers provide economical methods to automate previously manual operations. This is particularly occurring in palletizing and pick and place operations where automated palletizers and pick and place robot technology have become faster, more flexible and cost competitive in recent years. As workers'' compensation costs rise and technology costs come down, it is possible to justify automation today that may not have been economically or technically feasible in the past.
IEN: Will collaborative manufacturing play a role?
Thouvenot: Collaborative manufacturing will play a role as suppliers, manufacturers, and customers all try to find ways to gain a competitive advantage. Every one of these parties is finding it necessary to reduce costs and improve quality in a complementary manner. Collaborative manufacturing ensures that product requirements and equipment capabilities are clearly understood. The goal is to provide a win-win-win situation by improving or maintaining quality while reducing costs and minimizing the impact on profitability.
We are exploring this with our suppliers at Alvey. We involve our suppliers in equipment design and manufacturing to ensure that we provide the best value for our customers.
IEN: What is the future of third-party logistics vendors in plant floor material handling operations?
Thouvenot: 3PL vendors appear to be playing a larger role with manufacturers. In some instances, the 3PL is receiving the raw materials and supplying them to the manufacturer as required as well as handling the finished product coming out of the manufacturing facility. The 3PL is moving closer to the core manufacturing operations. This may mean that the 3PL is actually receiving single cases of product and handling the palletizing operations that have traditionally been part of manufacturing.
The challenge for automation suppliers is that we now have to coordinate requirements and expectations with the 3PL and the manufacturer as we design and implement automation solutions.