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Here’s How Supply Chain 4.0 Makes Your Organization More Efficient

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Archives, Global Logistics, Global Trade Daily, Warehousing

Here’s How Supply Chain 4.0 Makes Your Organization More Efficient

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There’s a growing interest in Supply Chain 4.0 technology, especially as logistics professionals cope with stock shortages, port delays, and other challenges. Advanced tech can boost productivity in warehouses and all other points of a product’s journey to its destination. Here’s a closer look at what supply chain management can do for those who invest in it.

Facilitating Productivity and Reducing Worker Strain

Hard physical labor is a regular occurrence for people who have many supply chain jobs. Getting relevant training about how to bend, lift, and avoid strain from repetitive tasks can pay off in helping them stay injury-free and able to give maximum output. However, some companies are also investing in robots to help even more.

In one case, a distributor of adult incontinence products pursued robotic palletizing to streamline its receiving process. An associate begins by scanning a label on a carton to tell the robot a product is on the way that must be unloaded soon. The robot then refers to 20 patterns stored in its memory to decide how to build a pallet based on the incoming items. Once the robot creates the pallet, the goods go to a picking location or storage area.

There are many other opportunities to incorporate robots into Supply Chain 4.0, too. Some autonomous mobile robots bring goods to warehouse workers so those employees don’t have to leave their workstations and take the extra time and energy to replenish what they need.

Other robots work beside supply chain employees, saving them from some of the more laborious or error-prone tasks. Robotic machines excel at duties that require them to do the same movements for hours on end. They don’t get tired and, as a result, can prevent fatigue in humans.

Minimizing Packaging Waste

Supply chain management technology can ensure that each product shipped out of a warehouse has just enough packaging to protect it for the rest of its journey. Packaging has seen numerous user-friendly improvements over time. Creating perforations in materials lets people tear off pieces of cardboard or bubble wrap without using scissors.

Often, these perforations create a clean opening, helping people use the package for other reasons rather than throwing it away. Plus, many food wrap packages have integrated blades that let users cut the foil or parchment at the desired length. These examples show how smart packaging decisions can reduce waste, thereby pleasing consumers and helping manufacturers conserve resources.

However, there’s still room for improvement. Most people can recall occasions where they ordered a small item online and received it in a gigantic amount of packaging. That’s an unwanted outcome for everyone involved. However, Supply Chain 4.0 could make such situations happen less frequently.

Amazon developed a system that uses computer vision and machine learning to determine the type of packaging a particular item needs. The model can detect an object’s size, plus packaging details, such as whether an item is inside a plastic bag or a glass bottle. It also recognizes perforated parts of the package.

When the model has sufficient confidence in the ideal package for a given item, it can select it automatically, which increases efficiency. However, when the confidence level is lower, the system can flag that instance. In such cases, a human reviews the specifics and makes a judgment call. This approach helps Amazon meet its aims to cut down on packaging used. However, it also means items should arrive well-protected, but not overly so.

Achieving Better Visibility With Supply Chain 4.0

Supply chain management can get tricky because it often involves predicting demand based on known factors and making educated guesses about the unknown ones. What makes a certain product highly desirable worldwide while seemingly similar items don’t sell nearly as well? Which steps should supply chain professionals take to avoid long-term outages? Technology can help address those all-important questions.

One study found that artificial intelligence-driven demand planning caused a 50% drop in the product volume affected by extreme forecasting errors. Then, overall forecasting mistakes went down by a third. Those outcomes likely occurred because artificial intelligence can efficiently process large amounts of data and pick up on things humans would miss without technological help.

Decision-makers at computing brand Dell created a digital model of the company’s supply chain to help it cope with the ongoing semiconductor shortage. That tool enables running various simulations so that leaders can plan how to best handle the most likely scenarios.

One way Dell uses the simulated situations is to determine which products will probably become increasingly difficult to source. The company compensates by designing many items with interchangeable or reusable parts as one practical strategy for dealing with current and near-future conditions.

In another case, Unilever unveiled a digital twin that found the optimal batch time by calculating how long it took to produce the necessary quantities of shampoo. Having that data enables consistent production output and helps managers spot bottlenecks within a factory or elsewhere that could cause supply chain strain if left unaddressed.

Measuring Outcomes With Data and Metrics

Supply Chain 4.0 technologies typically don’t give optimized outcomes immediately after implementation. Instead, people in authority must examine the available data and make relevant tweaks accordingly.

Fortunately, that’s becoming easier to do with data analysis tools and sensors that automatically gather data for future review. Perhaps a factory leader hoped to increase weekly output by at least 25% after installing several logistics robots. A platform that collects and analyzes real-time data could show how close the facility is to meeting that goal.

Alternatively, a company may deal with a persistent problem of machines breaking down unexpectedly and significantly hindering the workflow. Connecting smart sensors to the problematic equipment could make it easier for maintenance workers to identify issues before they cause factory shutdowns.

Many decision-makers are understandably hesitant to invest in a lot of Supply Chain 4.0 technology at once. They’d prefer to see evidence of the positive effects of such spending first. Luckily, it’s progressively easier to get it.

A manager could start by calculating the money lost due to equipment failures. They could then measure how much smart sensors save by alerting people to issues before those machines become inoperable. Since so many connected technologies can gather data, they prove whether certain investments provided the efficiency gains people hoped for at the outset.

Supply Chain Management Technology Is Undoubtedly Valuable

These examples show how moving ahead with Supply Chain 4.0 plans could generate impressive results. However, that doesn’t mean people will get those advantages in all cases. They can massively raise their chances of success by considering the biggest supply chain obstacles affecting a business and how advanced technologies could help resolve them.

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Emily Newton is an industrial journalist. As Editor-in-Chief of Revolutionized, she regularly covers how technology is changing the industry.

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Archives, Global Logistics, Global Trade Daily, Warehousing

LET’S GET SMALL: WHY MICRO FULFILLMENT IS SO BIG RIGHT NOW

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It’s almost hard to believe that two years have passed since the onset of the COVID-19 pandemic and its merciless impacts on the supply chain, consumer behavior and how the world conducts business as usual. There is really nothing “usual” about conducting business nowadays, particularly for fulfillment operations in a myriad of sectors now saturating the e-commerce market. 

The fact of the matter is that e-commerce is no longer just thought of for a holiday list or bargain deal that cannot be found in traditional brick-and-mortar shops. E-commerce is becoming more of a first option for some and a permanent solution for others. Grocers, retailers, department stores and beyond are feeling the full effect of the e-commerce trend and despite the pandemic, it could very well be here to stay. 

So, how does this change the way fulfillment providers conduct operations? According to KPI Solutions’ Brittain Ladd, micro fulfillment is the key to capturing lost dollars and keeping up with demand.

“About 20% of all sales today are direct-to-consumer,” Ladd shares. “Prior to the pandemic, only about 3% of grocery sales were online. And only about 6% of all retail sales were online prior to the pandemic, so we’ve seen a massive shift. Grocery retailers and retailers of general merchandise had to change their business models to keep up with direct-to-consumer demand.”

Ladd serves as the chief supply chain and marketing officer with Kuecker Pulse Integration (KPI) in addition to his position as a Forbes Councils member. KPI Solutions is the result of an integrated partnership between Kuecker Logistics Group Inc., PULSE Integration and QC Software. Known best for bringing system integration and robotics automation to a variety of sectors, KPI Solutions approaches fulfillment operations uniquely by implementing and innovating their own software to meet demand.

“KPI Solutions has partnerships with leading robotics companies, and we can install basically any system that exists,” Ladd says. “We work with some of the largest global companies to help them automate their fulfillment and sharpen their strategy to identify more cost effective and innovative ways to meet customer demand. Consumers want more speed, especially now, and a lot of analysts are confused because they fail to realize that the goal isn’t to just deliver groceries in 10 to 15 minutes, it’s to deliver apparel, shoes, electronics and other products as well.”

So, where does micro fulfillment fit? And more importantly, how can it support fulfillment operations now and in the future? Let’s start by understanding how companies–such as grocers—a re struggling beyond the surge in e-commerce. Ladd shares that contrary to the widely held belief, grocers are suffering significantly with e-commerce, as they not only spend more to fulfill these orders, but they must keep up with the labor involved in third-party services, which further complicates the process.

Keep in mind, grocery retailers are now faced with a new wave of demand and speed. Ladd shares that companies in Europe that have entered the U.S. market, such as Buyk and Jokr, are now offering “rapid grocery delivery” in as little as 10 minutes.

“On average, grocery retailers lose anywhere from $7 to $15 on every online order they fulfill,” Ladd says. “And in some cases, they can lose as much as $25 on every online order they fulfill. Most retailers barely break even on any of their curbside pickup orders, except for the product since it’s a little higher value. 

“Imagine being a retailer who is now forced into a model where they’re having to change everything they do to meet the changing demands of consumers, but everything the consumer wants them to do the retailer loses money on. That’s the challenge.”

That’s also where micro fulfillment centers and technology can not only capture these costs but turnaround the way e-commerce fulfillment is streamlined. 

Geek+, Berkshire Grey, AutoStore, and Addverb Technologies are a few of the companies that are innovating fulfillment operations through automated robotic systems. These fully automated systems reduce the chances for human errors with mobility and capability of reaching inside inventory bins quite literally to fulfill orders. Ladd shares that most of these automated solutions cost around $1.2 million to $1.5 million with a return on investment realized within 18 to 24 months, paying for themselves while re-inventing fulfillment.

“The best way I can describe it is like holding a Rubik’s cube in front of you,” Ladd says. “Each of the cubes has some type of inventory inside and sitting on top of the Rubik’s cube are robots that go back and forth and side to side reaching down and picking up these cubes and moving them from one side to another, pulling out inventory. That’s exactly what they do as a robotic picking and fulfillment system.”

Embracing technology is what comes full circle for retailers attempting to overcome the e-commerce surge. And options such as these not only fully automate fulfillment processes but keep human involvement to a minimum. Retailers are catching on and the U.S. market is now starting to see what the European market has already adopted. In fact, Ladd shared that three European companies have recently entered New York City, and they are bringing exploding growth with them.

What makes these systems even more enticing (beyond the fact that they are fully automated) is the ability to operate after-hours–or in the dark when stores are closed. Micro fulfillment centers are intelligent enough to automate the fulfillment process, but small enough that grocery retailers can install them inside their stores–completing all of the fulfillment tasks and mileage usually completed by employees. 

“These systems are quite easy for retailers to embrace and adopt,” Ladd says. “Companies including Kroger, H-E-B, Albertson’s, Instacart and DoorDash are among the more recognized brands that are exploring these innovative options and either installing these systems or exploring how to use these systems. Make no mistake, the future of retail is robotics. Retailers that don’t embrace robotics will never be able to survive long term.”

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Brittain Ladd, chief supply chain and marketing officer with KPI Solutions, is recognized as a leading expert in business strategy, supply chain management, logistics and last-mile delivery. He was one of the first individuals to research, design and recommend that retailers install micro-fulfillment centers in their stores and chains.

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Archives, Global Trade Daily, Software, Special Reports

Automation Versus Human Innovation: How To Engineer An Equitable Economy

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Are some companies moving closer to having more robots than employees?

Recent studies indicate a trend in that direction.

The data: Research from Google Cloud shows two-thirds of manufacturers who use artificial intelligence in their day-to-day operations say that their reliance on AI is increasing. And a report from PwC predicts that by the mid-2030s, up to 30% of jobs could be automated.

The key questions: How much automation vs. how much human innovation? Which is better for a sustainable economy? And why are some businesses spending more on automation than people?

Thought leader’s take: Jarl Jensen (www.jarljensen.com), ForbesBook author of The Big Solution: Deactivating The Ticking Time Bomb Of Today’s Economy, says large inequities between the labor class and corporations exist in part because of cheap lending practices, enabling corporations to borrow large sums from banks – and one result is the trend toward more automation.

“Corporations would rather have an employee base full of robots, and a select few humans to monitor the robots, because it saves them money in labor cost,” Jensen says.

“Borrowing without a maximum limitation means it is easy, and often more affordable, for corporations to invest in automation or robotics than their labor force. It is cheaper to take a loan from a bank to finance the purchase of artificial intelligence software than it is to re-train workers or engage in improving work skills. The unfortunate reality of our economic system is that there is no incentive for banks to stop making loans to rich people and corporations – even if the end result is a decrease in jobs due to automation and artificial intelligence.”

Jensen thinks the economy can be engineered to make it more equitable – ”an economy for the people.” These are three of the tools he suggests to fix the economy:

Direct deposits. “The first and best tool at our disposal is the money that a new and better version of the Federal Reserve would deposit directly into the bank accounts of every American of working age,” Jensen says. “This is not a basic income. It is an essential liberty.”

Jensen’s idea is that the direct deposits would be made for future work. The amount each working person would receive would be adjusted according to the signals being received from the economy.  “The way out of the debt trap is direct deposits,” he says. “Direct deposits put the people first. It forces the system to adjust to the needs of the people. The money we’re talking about for these direct deposits is money that the Fed simply creates out of thin air like it does when it issues money for loans to banks. But this money is not creating a debt that has to be repaid, thus does not grow the national deficit or become a debt burden for the Americans who receive it.”

Blue sky markets. Jensen describes blue sky markets as money for businesses that pursue the common good. This tool, he says, takes big problems out of the government’s hands and puts them in the hands of entrepreneurs. ”Blue sky markets issue money directly to fund commodity exchanges that effectively solve these big problems,” he says. “They create money for the purpose of fixing what is broken and making a more sustainable, stable, and compelling future.”

One example of implementing this tool is in addressing climate change. “Businesses would bid on the exchange to remove CO2 from the atmosphere,” Jensen says. “Money that is not debt-based, taken directly from the Federal Reserve, would pay the lowest bidder to remove the CO2. Competition for profits would compel entrepreneurs to figure out how to do it efficiently and effectively.”

New kind of savings account. “Today, any money you put in the bank doesn’t sit in your account,” Jensen says. “It gets repurposed. The bank uses it to invest, to loan out to other people or entities, and to create more debt. But if, alongside these new direct deposits, you had new high-interest bank accounts that are accessible to everyone, then that would keep some of the money out of circulation. Many people would choose to save the money and collect the interest.”

Jensen says the money to pay those higher interest rates would come from the Fed. With more people saving because of this high-interest incentive, and much less of that money going out in circulation, he reasons that inflation would not set in despite all the direct deposits and blue sky markets. “And as a huge bonus,” he says, “this system makes planning for retirement a lot easier.”

“Having an economy for the people is all about reimagining how we value money and restructuring how banks do business,” Jensen says. “It’s about real freedom, sustainability, and the optimization of society.”

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Jarl Jensen (www.jarljensen.com) is ForbesBook author of The Big Solution: Deactivating The Ticking Time Bomb Of Today’s Economy. He’s the founder and president of Inventagon, a company creating simpler research and development solutions for organizations across the globe. Jensen holds patents for medical technologies that have reached sales of over $1 billion. He founded EuroMed, a company he sold in 2016, and has written five books about the economy and its relationship with society.

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SCALLOG is Supported by the Intralogistics Specialist SPAN to Accelerate its Development in the Middle East.

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As part of its international expansion strategy, SCALLOG announces the signing of a commercial agreement with SPAN, a renowned player in the optimization and automation of distribution centers in the Near and Middle East.

During the Dubai World Expo where French innovation shines, SCALLOG agreed to enter into a partnership agreement with recognized intralogistics expert SPAN to market their “Goods to Man” robotic solutions in the Middle East, particularly in Egypt and the Arabian Peninsula, the United Arab Emirates, and Saudi Arabia. It marks SCALLOG’s desire to develop in a market with strong development potential, in search of innovative solutions to build the logistics of the future by capitalizing on a regional base, expertise in logistics, numerous references and a long-term relationship with SPAN. As Olivier Rochet, CEO of SCALLOG tells us: “We are pleased to partner with an intralogistics expert like SPAN who will bring our value proposition to the fastest-growing markets in the Middle East. A “made in France” robotic logistics solution, highly flexible and scalable, that automates and optimizes order picking, with agility and resilience, and with a constant focus on reducing costs and lead times.


An extremely heterogeneous and competitive market in search of innovation.

As in Europe, the Covid-19 epidemic in the Middle East and Arabian Peninsula has accelerated changes in buying behavior and triggered a boom in e-commerce. According to the latest Market Research Feedback study commissioned by Tiktok, 90% of the users of this social network in Saudi Arabia, 83% in the United Arab Emirates, and 79% in Egypt have significantly increased their online shopping habits in 2020. In order to meet the new omnichannel requirements for consumers, the distribution centers in these countries must now rationalize and automate their logistics operations to increase productivity and accelerate their throughput while limiting their labor requirements.

Hoda Daniel, Strategy and Communication Director at SPAN, explains to us the specific features of the market: “The Middle East is a heterogeneous market, as diverse as the countries it comprises. Today, three countries stand out in terms of investment and the deployment of intralogistics resources: Egypt, the United Arab Emirates, and Saudi Arabia. However, they each have their own criteria in terms of regulation, infrastructure, etc… Companies in these countries are therefore looking for a local partner, an expert in intralogistics, who perfectly understands their specific needs, provides tailored solutions and builds long-term relationships, just like SPAN.”

A leading player in intralogistics in the Middle East

Founded in 1989, SPAN is a key player in the modernization of intralogistics in distribution centers, in terms of advice and technological solutions. With a team of over 370 associates and a presence in Dubai, Doha, Abu Dhabi, Riyadh and Beirut, the company has unrivaled experience in its market with projects completed in over 30 countries across all sectors of activity. In addition, it is well known for its wide range of automation solutions, from the most traditional to the most innovative, for optimizing all warehouse operations.

Walid Daniel, CEO of SPAN, comments, “Faced with the numerous upheavals caused by the health crisis, from the impact on demand to the changes in buying habits, coupled with the instability in our region, we are now witnessing a fragmentation of the intralogistics market. In this context, we wanted to expand our technological offer of mobile robots and shelving, more flexible and less expensive than traditional handling systems, in order to respond to the growing demand for agility and efficiency from our clients in the face of a new economic situation, namely a recovery with many uncertainties.”

Three key factors motived SPAN’s choice to endorse and market SCALLOG’s solutions, in addition to cultural similarities and common values: the technological reliability of the robotic solution proved in the field in Europe and transparently described in a technological roadmap, a value-added approach which means technology is used to optimize processes and a perfect understanding of operational requirements in order to build “tailor-made” solutions for clients.

Walid Daniel, CEO of SPAN, adds: “We are excited to add SCALLOG technology to our offer which moves us fully into intralogistics 4.0, combining automation, robotics, and data intelligence. This new offer guarantees our clients more agility and flexibility in their processes to adapt to changes and be creative in their business”.

Remi Badaroux, Partners Network Manager, concludes: “With SPAN, combining dual expertise, consulting and integration, our ambition, based on SCALLOG robotic solutions, is to quickly bring value to warehouses to enhance the customer experience and the competitive edge of businesses in the Middle East.

The two partners anticipate the first deployments of SCALLOG solutions in the first half of 2022.

Supply Chain Industry
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Factors that are Reshaping the Supply Chain Industry

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In the modern supply chain, the technology and software you use are as important as your strategies. Plenty of decisions and actions you need to take now happen in the digital world. So, you must pick the right technology if you want to see better efficiency in your chain. In essence, choosing the solution you want to use can make or break your position on the global stage. Hence, technology is and will stay one of the main things that define the game. But, what are the exact factors that are reshaping the supply chain industry? Well, that’s what we’re here to find out.

Last year, COVID-19 took the supply chain to a new place, but not all in a bad way. The changes that took place opened new opportunities and created new practices for companies. We found ways to improve agility and eliminate risks, and things are only getting better.

To figure out how to make them better for your system, take a look at the key things that are transforming the industry at the moment.

Artificial intelligence

Algorithm-based decision-making software and data analyzers are being adopted in every niche, so it’s clear that the era of useful AI has arrived.

When it comes to the supply chains, among other things, AI can help you eliminate human error and reduce costs. It’ll allow you to restructure workflows, so all your workers can be more focused and productive. The technology will support them and make their jobs easier. We’ll explain how this happens a bit later.

The pace of technological change

Technology is developing faster than we can learn to use it. Let’s take eCommerce as an example. It provided people with a whole new way of shopping and took the world by storm. All of a sudden, you’re able to find anything you need and have it delivered to your door without ever having to leave the comfort of your home. Thanks to it, customer demands and expectations have changed. Now, they expect quick and even same-day deliveries. So, the logistics industry has to respond to that to stay in favor of people.

As a company, the only way to stay relevant is to build a reliable infrastructure and learn how to use new technology developments. Experts believe that online and mobile shopping will be the preferred way of buying for the majority of people in the future. Even today, people are getting everything from groceries to appliances online, so why would that change in the years to come?

To update your system, try to make your processes more streamlined. That will give you a better chance of keeping up with modern timeframes.

The Internet of things

We can’t talk about the factors that are reshaping the supply chain industry and not mention the Internet of things. Although most people will associate the term with smart home appliances, this technology is actually invented to deal with sensors and tracking equipment.

So, the IoT is what you’ll use if you want to reduce commercial warehousing costs. However, it can help you do much more than just that. With it, you can connect all the products, people, and processes within your organization and share information among them in real-time. Just like that, everything becomes streamlined, and your productivity goes up.

Automation and robotics

Of course, people have been using task-specific robots for decades in industries such as automotive. However, the latest generation of robots can learn how to do multiple tasks, so they have much more potential.

In supply chains, you can find a use case for these almost anywhere. Add AI into the mix, and you quickly realize that robots can bring many new things to manufacturing processes and reduce staff costs. With time, more and more repetitive or dangerous tasks will be performed by these.

Big Data

Big Data is used to track data and measure the performance of factories in real-time. In past times, to survey workers, you had to put an entire factory under surveillance. But today, modern sensors and networks give us insights that we couldn’t get before. You can even collect data on each and every employee if you want to. This way, you’ll spot problems much more easily and fix them sooner.

When you remove the bottlenecks in the delivery process, you’ll also improve the lives of your workers. You’ll streamline their roles, and they won’t waste time on unnecessary or frustrating tasks. If you rely on Big Data-driven decision-making, you’ll create a leaner business model and reduce wastage.

3D printing

If we’re talking about prototyping new products and designs, there isn’t a tool as useful as 3D printing. Companies that invested in it say that they managed to halve their prototype production times, and that’s a huge thing. If you have to wait for weeks until you get parts to start working, that creates problems right down the supply chain. It lengthens the process and increases the costs. On the other hand, 3D printing alleviates supply chain weaknesses that already exist.

Use it, and you can apply design iterations to the molds within hours. So, you’ll be speeding up the process and encouraging the closer engagement of product designers and the manufacturing team. And for that, 3D printing is one of the factors that are reshaping the supply chain industry.

Factors that are reshaping the supply chain industry – delivered

Incredible advancements in technology are at the root of all factors that are reshaping the supply chain industry. If you fail to incorporate them, you will fall behind. Therefore, follow the latest trends and introduce the changes that will streamline your processes, make your business functioning more efficiently and productive.

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Deon Williams is a freelance writer with a degree in systems engineering. Although it’s not his main job, he loves to write articles and share his expertise. In the past, Deon helped companies like zippyshelldmv.com to streamline their processes and increase their earnings. When he’s not working, he loves to read in his comfy chair and play basketball with his two sons. 

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5 Innovations in Manufacturing Processes and Their Effect on the Bottom Line

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Manufacturing is a rapidly evolving industry. With a broad spectrum of sectors depending on manufacturing, modern facilities are often quick to adopt new technology that improves on their existing processes.

The rise of automation, artificial intelligence (AI) and data have created a wave of digital transformation. As manufacturing grows and becomes increasingly competitive, capitalizing on Industry 4.0 innovations can determine whether or not a company will succeed.

Here’s a look at five of these innovations and how they affect the bottom line.

1. Cobots

Robots aren’t new in the manufacturing industry. But as automation has grown, new approaches and technologies have emerged that can take its benefits further. Collaborative robots, or cobots, are one of the most significant of these upgrades to factory automation.

In a 2021 study, 44.9% of surveyed businesses said that robots are an integral part of their operations. Of those companies, 34.9% had adopted cobots. Cobots have slowly become more popular as manufacturers have realized the limits of traditional automation. Other robotic solutions are expensive and inflexible, making it difficult to scale, but not cobots.

Since cobots work alongside humans instead of replacing them, they typically automate fewer processes at once. Consequently, they’re often more affordable than traditional automation and easier to implement. Manufacturers can then automate one process at a time, slowly scaling up to meet demand or new challenges.

This incremental approach to automation removes the high upfront costs and disruptions of traditional automation. As a result, cobots enable manufacturers, especially smaller businesses, to scale up and down with ease. These companies can then enjoy quicker, higher ROIs.

2. IoT Sensors

Another growing innovation in manufacturing is the implementation of internet of things (IoT) sensors. While these technologies aren’t a manufacturing-specific phenomenon, they hold considerable potential in this sector. Perhaps their most popular and impressive use case is predictive maintenance.

Predictive maintenance improves on traditional maintenance schedules by avoiding both breakdowns and unnecessary repairs. According to a Deloitte report, it reduces maintenance costs by 25% on average. That’s an impressive figure on its own, but it also reduces breakdowns by an average of 70%.

Considering that an hour of downtime costs more than $100,000 in 98% of organizations, that adds up to considerable savings. Predictive maintenance isn’t the only application of IoT sensors in manufacturing, either.

Manufacturers can also use these sensors to gather data points throughout their operations. This data can then reveal areas of potential improvement, enabling ongoing optimization. The longer manufacturers use these technologies, the more they can save through them.

3. Additive Manufacturing

One recent innovation that is specific to manufacturing is 3D printing, also known as additive manufacturing. While this technology is most well known as a tool for hobbyists, it originated as an industrial production technique. Recent advances have made it a more viable solution, leading to a comeback in industrial manufacturing.

Additive manufacturing lets manufacturers produce parts and products as a single piece instead of assembling multiple smaller components. Like mil-spec buffer tubes, which are made of a single piece of aluminum, this improves products’ strength and resiliency. As a result, they produce fewer defects, improving the company’s bottom line.

Since additive manufacturing adds material instead of cutting it away, it also reduces waste. Manufacturers can get more parts or products from the same amount of materials. 3D printers also typically work faster than traditional production techniques, leading to a quicker time to market.

Additive manufacturing is also more energy-efficient. Some products, like car batteries, require a lot of energy to handle the sensitive materials they need, leading to higher costs. By reducing energy consumption through additive manufacturing, facilities can increase their profit margins. Alternatively, they could reduce end prices, selling more with consistent profit margins.

4. 5G Connectivity

Like the IoT, 5G isn’t strictly a manufacturing technology, but it has impressive potential for the sector. 5G networks aren’t widespread enough yet to bring substantial improvements to the consumer sector, but they’re ideal for manufacturing facilities. Their higher bandwidth, increased speeds and lower latency let smart manufacturing reach its full height.

5G networks can theoretically support up to one million devices per square kilometer, ten times 4G’s limits. That will allow manufacturers to expand their IoT infrastructure to virtually every machine in the facility. Lower latencies will allow these interconnected systems to communicate more efficiently and reliably, unlocking Industry 4.0’s potential.

With all of these machines connected to one another, manufacturers could create cohesive autonomous environments. If a disruption occurs in one process, machines down the line could know and adapt to it, minimizing its impact. As a result, manufacturers could maintain higher productivity levels, minimizing their losses from lost time.

5G lets manufacturers use technologies like the IoT and automation to their full extent. This leads to higher ROIs for these significant investments.

5. Machine Vision Error Detection

AI has many use cases in manufacturing, but one of its most enticing is machine vision. Machine vision systems let manufacturers automate quality control processes at both the front and back end of production lines. This automation, in turn, improves the efficiency and accuracy of their error detection.

When Heineken installed a machine vision quality control system in its Marseille, France bottling plant, it highlighted this technology’s benefits. The facility’s bottling machine operates at 22 bottles per second, far too fast for human workers to spot any bottle defects without stopping it. The machine vision system, on the other hand, can analyze bottles at speed with a 0% error rate.

Machine vision error detection lets manufacturers increase production while maintaining the same level of quality. Since these systems deliver a level of consistency impossible for a human, they’re also more accurate. As a result, facilities will also produce fewer defects.

Fewer defects translate into less waste, and faster checking enables increased output. These factors combined result in an improved bottom line.

New Technologies Make Manufacturing More Profitable

These five technologies aren’t the only ones pushing manufacturing forward, but they are among the most notable. As more facilities embrace these innovations, manufacturing is becoming a more profitable industry.

Technologies like these improve efficiency, minimize errors, optimize operations and more. Manufacturers that can capitalize on them early will ensure their future success, and those that don’t may quickly fall behind.

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Scallog Robotics at Newpharma: A Unique Realization in Collaboration with Smart Technics, Colruyt Group’s innovation pool

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In conjunction with the SITL trade show scheduled for 13-15 September at Paris Porte de Versailles, Scallog is announcing a new contract in Belgium for the robotization of the new logistics platform operated by Newpharma, the Belgian online pharmacy that serves 1 million customers in 12 countries across Europe. The deployment of Scallog’s Goods-to-Person robotics solution at Newpharma’s new distribution centre, which spans 20,000 sq.m and can be expanded to 50,000 sq.m, is scheduled for the fall of 2021 and will be overseen by Smart Technics Ventures, the innovation unit at Colruyt Group, which holds a minority stake in Scallog. At SITL, Scallog will also be showcasing the latest addition to its lineup, the Flexytote robot, which will be demonstrated at the Warehouse of the Future, an immersive environment at SITL devoted to the smart warehouse and including a full line of innovations for the intralogistics of the future!


 

Here’s a look at how Colruyt Group forged a successful collaboration among three businesses: Newpharma, Scallog and Smart Technics Ventures!

As part of its plans to consolidate its operations in Wandre, Belgium, Newpharma will soon be inaugurating its brand-new logistics centre located on a site near the Port of Liege. Plans for this next-generation warehouse were launched in 2019, supported by the Belgian retail business Colruyt Group. Pierre De Lit, COO at Newpharma: “Each year, Newpharma records double-digit revenue growth, which, over time, has forced us to spread our activities across several sites in Wandre and Tongeren. We have therefore decided to build one large distribution centre to support our further growth and optimise our logistics flows. We will gradually put the new installations into operation. In the first phase, the site will cover 20,000 m². In 2022, we will expand the site to 50,000 m².”

The consolidation of Newpharma’s activities is accompanied by extensive automation, supported by Smart Technics. The mission of the engineering team of this Colruyt Group start-up is to integrate innovative solutions in a sustainable way. Jeroen Theys, Managing Director at Smart Technics: “In this project, we integrated the Scallog solution into Newpharma’s operational flow, from the delivery of the goods by suppliers to the dispatching of the packages to end customers. Several options were considered each time to optimise stock management, order processing, order picking, packaging and ergonomics for the employees. We are very satisfied with the collaboration, which has resulted in a phased plan that will enable Newpharma to respond more flexibly to future market developments and secure further sustainable growth.”

“Scallog is already active in this sector in France. We are particularly pleased that we can equip the new Newpharma warehouse in close cooperation with Smart Technics today. This means that yet another Scallog picking facility will be operational in Belgium”, Caroline Dumas, International Business Manager at Scallog, adds.

Here’s a closer look at the Flexytote, which will be in operational readiness at the Warehouse of the Future!

As part of its ongoing desire to include more immersive demonstrations and experiences for its industry visitors, the 2021 SITL show is showcasing a 600-square-metre smart warehouse dubbed the Warehouse of the Future, presenting the most innovative solutions on a real-life scale. The space will feature the Flexytote, a new addition to the Scallog product line, working under operating conditions to automate the transfer, loading and unloading of bins and boxes so as to speed up the order picking process.

As a truly lightweight, flexible robotics alternative to traditional workflow automation systems, the Flexytote is based on a simple but effective principle: robots move two or three tiers of empty bins or boxes to picking stations, deposit them on order buffer racks, then retrieve them and transport them to the packaging area once the operators have completed the orders.

The logistics benefits are immediate: automated two or three-tier supply on-demand to the order buffer racks, elimination of load handling and transport by operators, less physical strain and accelerated order picking.

With flexibility that is unrivalled on the market, the Flexytote solution is easily integrated into any existing warehouse and can be adapted to all changes in order picking flows; the mobile robots follow optical markings on the floor that can be repositioned if and when required. The Flexytote solution also stands out for its load capacity of up to 250 kg, the background tasks it can undertake, its ergonomics and logistics productivity and its ROI in under 18 months.

automation
3pls, Archives, Global Logistics, Global Trade Daily

Infographic: Coyote Study Shows COVID-19 Impact on Supply Chain Automation

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To better understand how shippers and carriers are integrating technology into their operations today, and where they are investing for the future, Coyote Logistics conducted an in-depth research study in 2019.

Following a shift to digital adoption never seen before driven by the pandemic, Coyote revisited the topic in 2021.

This two-part infographic series outlines trends in supply chain automation based on feedback from over 850 global supply chain leaders. Below is part two with the remaining trends.

supply chain
3pls, Archives, Global Logistics, Global Trade Daily

Infographic: Supply Chain Leaders Weigh in on Ideal Balance of Tech and Human Expertise

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To better understand how shippers and carriers are integrating technology into their operations today, and where they are investing for the future, Coyote Logistics conducted an in-depth research study in 2019.

Following a shift to digital adoption never seen before driven by the pandemic, Coyote revisited the topic in 2021. This two-part infographic series outlines trends in supply chain automation based on feedback from over 850 global supply chain leaders. Below is part one with four of the top trends.

Security
Archives, Global Trade Daily, Software

An Exploration of Emerging Technologies for Facility Security

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Safety is a critical consideration for any workplace. Every business is subject to some amount of risk, and without proper precautions, companies could endanger employees or hinder their focus. While workplace safety isn’t a new concern, it is particularly prominent at the moment.

A 2020 poll revealed that only 65% of American workers feel completely satisfied with their physical safety at work. That figure is down 74% from the previous year and the lowest it’s been since 2001. Facilities must become more secure, and thankfully, new technologies provide a way forward.

While cybersecurity may get more press in conversations about security technology, recent advancements have pushed physical safety further, too. Here’s a closer look at some of the emerging technologies for facility security.

Artificial Intelligence

Artificial intelligence (AI) is one of the most disruptive technologies across industries today. As of 2020, 50% of surveyed companies had implemented AI. While its most popular use cases are in optimizing business processes or automating routine tasks, it has significant potential in security.

Machine vision algorithms can scan CCTV footage to recognize when someone is carrying a weapon. They can then instantly alert security staff or other employees, enabling quick, effective action. Since AI typically works far faster than manual processes, its speed could potentially save lives.

Similarly, AI could analyze audio signals to detect nearby threats. Studies suggest that people report only 20% of heard gunfire, mostly from being unsure of the noise’s source. AI could recognize these threats faster and more accurately, leading to timelier warnings and emergency calls.

IoT

Another emerging technology that has seen use cases far beyond security is the Internet of Things (IoT). IoT sensors’ ability to gather and send information in real-time makes them an indispensable facility safety tool. These sensors can virtually extend security staff’s reach, letting them monitor areas without traveling to them.

Even implementing IoT connectivity in everyday objects can improve facility security. For example, IoT-connected smoke detectors could send alerts to employees’ phones when they detect a fire in the building. These devices could then connect to a facility’s smart locks, opening safe passages while blocking compromised areas.

IoT connectivity can also improve workplace safety through predictive maintenance. These systems can make predictions about needed upkeep 20% faster and with higher accuracy than traditional means. Facilities can use this to keep gates and other security systems in optimal condition.

Drones

Compared to AI and the IoT, drone technology hasn’t experienced widespread adoption among businesses. Most commercial applications are in research, but they’re seeing increasing use as security tools, too. Like IoT sensors, drones let security teams monitor areas remotely, with the added advantage of omnidirectional mobility.

Facilities can use drones to get a bird’s-eye view of the property, potentially spotting things they may otherwise miss. Drones’ maneuverability can give teams access to areas that would be inconvenient or unsafe for workers to reach, too. Since flying is faster than walking, they make surveying a facility more efficient as well as more thorough.

Autonomous Robots

Some facilities have moved beyond remote-controlled drones to implement autonomous security robots. While these solutions carry higher upfront costs than traditional drones, they push their productivity benefits further. Without the need to control a robot, security teams can focus on other duties as these machines patrol, accomplishing more without extra staff.

Autonomous security robots may sound like a distant goal, but they’re already in use. LaGuardia Airport deployed robotic security guards in 2018, becoming the first major American airport to do so.

Security robots often feature capabilities beyond recording footage and sensing potential threats. Some have built-in facial recognition technology to identify known or wanted criminals, alerting security staff when they find them. Others can communicate with employees or visitors to help them navigate safely through the facility.

Disguised Barriers

Not every emerging security technology is as eye-catching as a robot, and sometimes, that’s by design. Such is the case with disguised barriers, which look like ordinary furnishings but protect buildings from vehicle-related accidents. These solutions keep employees, property and visitors safe without compromising a business’s curb appeal.

New technologies let companies construct robust protective barriers in unassuming shapes and sizes. As a result, a structure that looks like an ordinary flower planter can stop a 7.5 metric ton vehicle moving at 40 mph. The strength of these barriers ensures everyone inside is safe, while their design improves morale and attracts customers.

Traditional crash barriers may appear intimidating or overly industrial. These structures could drive customers away or make the workplace feel less comfortable, lowering morale. Disguised barriers remove these negative side effects while maintaining protection.

Innovative Materials

Novel construction materials are one of the innovations behind disguised barriers, but that’s not their only use case. Newly discovered or lab-grown materials can offer far more strength in a lighter or more flexible package. For example, graphene is so strong that if it coated a spider’s web, it could catch a falling plane without breaking.

These materials vastly improve the resilience of gates, barriers and other protective measures. Similarly, flexible options like graphene can form protective clothing for security guards or other workers who may encounter physical hazards. As research in this area continues, materials will keep getting stronger and lighter simultaneously.

Biometrics

Biometric security isn’t necessarily new, but new technologies are pushing it forward. Fingerprint scanners have become far more affordable and reliable than they used to be, letting many facilities replace outdated keycard systems. Physical biometrics themselves are no longer the peak of access security as behavioral biometrics gains traction.

Biometrics identify patterns in human behavior to distinguish between people. While most of these systems analyze computer use patterns like keystrokes, some can measure physical behaviors like someone’s gait or speech. These actions are harder for someone to fake, protecting restricted access areas from fraud.

Behavioral biometrics hasn’t seen much use in physical security yet, but as technology develops, it could. These systems can bolster traditional methods like passcodes and keycards to maintain a high bar for security.

New Technology Can Make Facilities More Secure

Every workplace has hazards, whether people realize it or not. As criminals’ methods become more sophisticated, so too must the security systems that stop them. These new technologies represent the latest in safety innovation.

Many of these technologies are still in their early stages, but they’re growing quickly. Before long, they could define modern security, making workplaces safer in the face of rising threats.