IEN: How can this sector meet rising demand for greater automation and flexibility?

Woodson: Automated material handling equipment such as: automated storage/retrieval systems, conveyors, robots, sortation systems, automatic guided vehicles, floor and ceiling monorail systems, order pick systems, carousels, palletizers, depalletizers, elevators, shrink wrap machines, and flexible warehouse management system software, have all been in use for many years. The equipment and technology in this sector is plentiful and currently waiting to support the projected increase in automation and flexibility.

IEN: What innovations are in store for users of equipment, systems, components, materials, and software?

Woodson: The wave of RFID technology will represent the largest innovation for these users for many years to come. Initially, test pilot programs will fit the equipment and technology to each organization. This will lead to a corporate RFID implementation, which will generate a complete corporate-wide product flow picture. This new information, once understood, will create a better knowledge base to more effectively manage each organization's daily operations. The final challenge will be taking these individual corporate applications and tying complete supply chains together, providing complete product lifecycle visibility to all involved. Challenges of a shared database, competitive pricing, and Internet security will all need to be overcome. Each of these steps will create tremendous knowledge, in turn creating efficiencies in local, national, and global operations unheard of today. Every organization will need to implement this technology at some level to compete against those that already have.

IEN: What advances do you see in plant floor connectivity? Web services? Remote material handling?

Woodson: Plant level control software such as Wonderware and Control Logix currently interconnect all programmable logic controllers (PLCs) for manufacturing equipment together to allow for central monitoring and control. Advances in this industry are being realized as each new version of PLC software moves closer to the more common development platforms of Unix, Oracle, and Windows, which will allow further integration into corporate host computers.

Web services currently can support the requirements for the implementation of all the current initiatives. Advances will need to be made in security and wireless connectivity.

Remote material handling has been in use for many years. Warehouse inventory management (shipping/receiving) is initiated remotely by purchasing or sales; the warehouse management system software then automatically manages the receipt or sales order fulfillment, communicating any issues to the appropriate personnel and updating the host computer inventory log. The current warehouse management systems are extremely reliable, easy to use, and affordable. Most can easily manage the current technology initiatives with little if any advances.

IEN: Where are other R & D hot spots?

Woodson: RFID, Internet Security and PLC software platform development are the three main R & D hurdles today.

IEN: Will wireless become more prevalent?

Woodson: Yes, as this technology is understood and embraced, wireless connections to networks and the Internet will become much more prevalent. To eliminate the need for a hard-wired network creates tremendous savings, flexibility, and functionality. Wireless networks currently in use include: automated storage/retrieval machines, automatic guided vehicles, forklifts, route trucks, bar code/RFID scanners, RFID active tags, personal computers, telephones, thermometers, etc., with many more to come as this technology is more fully utilized.

IEN: How can downtime issues be resolved? Through RCM, web-based monitoring, embedded maintenance? Other solutions?

Woodson: Downtime for material handling equipment applications has never been acceptable. Most equipment marketed today can maintain a 98% uptime if properly maintained and an adequate spare parts program is in place. Corporate commitment to maintenance and spare parts inventory is all that is required, as current technology exists to support even the most demanding equipment to the highest degree.

IEN: What progress do you see in meeting safety and security goals?

Technology currently exists in the material handling industry to respond to current and most likely all future safety and security mandates. This is certainly a "wait and see" subject but capabilities within current equipment and software designs are both flexible and extensive.

IEN: Will collaborative manufacturing play a role?

Woodson: Manufacturers working together with the common goal of bringing a product to market more quickly, and at the best price, will create industry leaders. Material handling system designs can currently support this approach to market.