Five ways automated bulk material handling equipment improves efficiency

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Five ways automated bulk material handling equipment improves efficiency

Five ways automated bulk material handling equipment improves efficiency

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Dec 30,22

Manufacturing companies can become more agile and cost-effective when bulk material handling is more efficient. There are many ways to achieve that goal, but automation is one of the strongest, says Emily Newton.

Five ways automated bulk material handling equipment improves efficiency

The manufacturing sector is no stranger to automation, though much of its implementation remains on factory floors. If the industry hopes to make the most of this technology, it should also expand it to earlier supply chain and processing workflows. Automated bulk material handling, in particular, can bring significant efficiency improvements.

Transporting and sorting raw materials is a critical but often inefficient step in manufacturing. Automating various workflows throughout this process can change that, leading to shorter lead times, more flexibility and better operating margins. Here are five ways automation enables those benefits.

1. Streamlining workflows

The most straightforward way automated bulk material handling boosts efficiency is by performing the work faster. Even experienced human workers face physical limits on how fast they can move, especially when factoring in safety. Consequently, machines can perform repetitive, physically demanding tasks much faster.

Some manufacturing lines have sped processes from six hours to just two by automating the slowest parts of the line. Typically, these are either data-heavy, monotonous or heavily physical tasks, which describes much of bulk material handling. Machines can’t get tired or distracted, so they can also deliver this same speed 24/7.

Automating parts of the workflow also frees employees to focus on other aspects of the process. As a result, manual tasks become more efficient, too, leading to considerable time savings.

2. Minimising errors

Another way that automation can streamline bulk material handling is through error reduction. Sorting, tracking and picking tasks rely on fast, accurate decision-making. Experienced workers can perform these jobs with a high degree of accuracy, but they’re still prone to mistakes, especially late into a long shift.

Automation bases each decision on the same hard data, so as long as its tools for measurement are accurate, it’ll deliver the same results every time. Machines are also typically better at data-heavy analysis tasks than humans, further reducing errors.

Human error accounts for 23 per cent of all unplanned downtime in manufacturing, and 82 per cent of companies have experienced these outages within a three-year period. Bulk material handling processes will avoid this downtime by minimizing mistakes through automation and maintaining higher productivity.

3. Preventing injuries

Similarly, automated bulk material handling helps prevent workplace injuries. Accidents are likely and dangerous in processes dealing with heavy raw materials and intensely physical workflows like these. On top of endangering employees, safety incidents cause significant downtime, but automation provides a solution.

The safest way to address a workplace hazard is to remove it entirely. Automation gets close by distancing humans from these hazards. When machines handle the most hazardous parts of the workflow, employees won’t be close enough to these risky processes to be in danger.

Automated systems can also take over tasks that would cause less dramatic but still damaging repetitive strain injuries. This safety boost would help employees work as efficiently as possible, as their work wouldn’t make them as sore or tired.

4. Improving machine maintenance

Another type of unplanned downtime automation prevents is that relating to maintenance issues. Bulk material handling equipment undergoes heavy stress, sometimes dealing with tens of thousands of pounds of materials. Consequently, if companies don’t keep machines in top condition, they could break, disrupting workflows.

One of the best ways to prevent equipment breakdowns is through predictive maintenance. This involves using automated Internet of Things (IoT) sensors to monitor machine performance, automatically alerting employees when it falls outside acceptable parameters. The company can then repair the equipment before it becomes a larger issue.

This automated approach to maintenance also reduces unnecessary downtime from unneeded repairs. Because these fixes are need-based instead of schedule-based, machines will only go offline for upkeep when necessary, further saving time.

5. Mitigating labour shortages

Automated bulk material handling equipment can also improve efficiency by lessening the impact of labour shortages. The U S. manufacturing industry could have 2.1 million unfilled positions by 2030 as its current workforce ages and fewer young employees enter the sector. Automation won’t reverse that trend, but it can mitigate its consequences.

Automation means manufacturers and their suppliers don’t need as many employees to complete the same amount of work in the same time frame. The people they do retain will have more time to accomplish other tasks as machines handle the most dangerous or repetitive workflows. As a result, facilities can effectively expand their workforce without needing to fill more positions.

Thoughtful automation complements human workers so both can reach peak productivity, with each focusing on what they’re best at. This job restructuring helps accomplish more at once, so an inability to acquire new talent is less impactful.

Automated bulk material handling has many benefits

Manufacturing companies can become more agile and cost-effective when bulk material handling is more efficient. There are many ways to achieve that goal, but automation is one of the strongest.

Automated bulk material handling equipment is becoming increasingly accessible. These efficiency benefits will grow as technologies improve, helping manufacturers reach their full potential.

About the author:

Emily Newton is a tech and industrial journalist and the Editor-in-Chief of Revolutionized Magazine. Subscribe to the Revolutionized newsletter for more content from Emily.