CPG manufacturers are caught in a pincer as the world of manufacturing continues to evolve at an accelerating pace and the skilled labor market falters at the same time. More and more of the mechanically inclined and hard-working Baby Boomer generation are retiring at a rate of 10,000/day. At MEMCO, we hear our clients tell us time and again that they are battling raw goods price increases, shrinking labor availability, understaffed engineering teams and increasing consumer reluctance to accept increasing prices. These pressures all create a difficult environment for CPG manufacturers to thrive in.

Increasingly, these manufacturers are turning towards MEMCO for innovation and Industrial Transformation as a way to stay ahead of the curve. Through a combination of machinery, robotics, digital assets, and data analytics all bundled into a Kaizen approach of Continuously Improving on an operation, these companies are able to massively reduce their costs and exposure to risk. In a post-Covid world, de-risking and doing more with less is such a common boardroom conversation it has become almost cliché. We at MEMCO live for those conversations and will happily discuss any ways to improve a business from the intricacies of a PM schedule with a Maintenance Manager all the way to nuances of a balance sheet with a CFO to find alignment across an organization.

MEMCO’s clients appreciate the approach of the Future Now program to help them achieve these goals of reducing cost and risk. Through this, MEMCO brings together cross-functional teams to align on a cohesive Industrial Transformation for a plant or series of plants nationwide. This involves MEMCO bringing a full team of Industrial, Electrical and Mechanical engineers along with sophisticated Business Analysts, all coming together to present solutions to a company’s Apex problems.

No longer do you have to be concerned about how a project will be justified or whether an engineering team wrote an RFP in just the right language so that multiple engineering firms are able to provide the right solution you’ve pictured. MEMCO will work directly with your team from the shop floor to the C-Suite and make sure all team members are aligned on the most effective methods of improving an operation. Our clients have told us how they’ve appreciated being able to focus on solving problems rather than spending their working hours trying to schedule all the right teams together to scrounge their shop floor and accounting software to try to find exactly the right problem to solve to make sweeping changes.

Experience the future of manufacturing with MEMCO as we use our experience visiting and implementing value-added solutions to thousands of CPG and F&B plants to help enable sustainable growth and massively reduce the risk in your operation.

In the ever-evolving landscape of the Consumer Packaged Goods manufacturing industry, a significant shift is imminent – the Silver Tsunami. As the baby boomer generation enters retirement, this tidal wave of experienced and dedicated talent departure will transform the way work is done on the manufacturing shop floor.

The retiring baby boomer machine operators brought with them years of experience and a wealth of knowledge, valuing hands-on expertise and time-tested practices. They preferred a more traditional approach to technology, often relying on their skills and instincts. On the other hand, the rising Gen Z workforce embraces technology as an integral part of their lives. They are tech-savvy, adaptable, and thrive on continuous learning.

To ensure seamless integration of Gen Z operators, manufacturers should cater to their unique work styles and preferences. Manufacturing equipment needs to be designed with intuitive user interfaces, enabling Gen Z to effortlessly navigate through the complexities of modern systems. By doing so, we empower this new generation to leverage their natural technological prowess to drive efficiency and innovation on the shop floor.

Thoughtful equipment designs also play a crucial role in making preventative maintenance tasks more manageable. By providing Gen Z operators with equipment that simplifies maintenance processes and offers easily accessible information, they can proactively address potential issues and maintain the machinery with confidence.

Furthermore, embracing PLC Line Control is another game-changer for the industry. By providing real-time data insights to Gen Z operators, we cater to their data-driven decision-making preferences. This allows them to optimize processes, enhance efficiency, and streamline production based on evidence and statistics.

We understand the significance of harnessing the potential of the Silver Tsunami and catering to the distinctive work styles and preferences of Gen Z machine operators. Embracing this transformation will undoubtedly position agile consumer packaged goods manufacturing operations at the forefront of innovation, productivity, and success in the industry’s new era.

Together, let’s ride the Silver Tsunami towards a prosperous and data-driven future for the industry.

If you’d like help modernizing your factory operations, please don’t hesitate to contact us at info@memco.ai

In the rapidly evolving landscape of Consumer Packaged Goods (CPG) manufacturing, embracing automation and robotics has become essential to stay competitive. Yaskawa Motoman, a renowned leader in industrial robotics, offers a range of solutions tailored to the unique needs of the CPG sector. In this blog post, we’ll dive into a thorough analysis of Yaskawa Motoman robots, exploring their benefits not only as robot solutions but also as a business. By the end, you’ll understand why robots on the factory floor are crucial and discover the best use case examples with the strongest Return on Investment (ROI).

1. Unparalleled Performance and Precision: Yaskawa Motoman robots have gained a reputation for their exceptional performance and precision. Whether it’s pick-and-place tasks, palletizing, packaging, or assembly operations, these robots deliver consistent results with remarkable speed and accuracy. By leveraging their advanced kinematics, vision systems, and intelligent programming, CPG manufacturers can achieve unparalleled quality and efficiency, resulting in enhanced product output and customer satisfaction.
2. Streamlined Workflow and Efficiency: The integration of Yaskawa Motoman robots optimizes workflow and efficiency on the factory floor. These robots excel in repetitive and labor-intensive tasks, eliminating human error and reducing cycle times. By automating processes such as material handling, sorting, and machine tending, manufacturers can unlock significant productivity gains and reallocate human resources to more value-added roles. The result? Streamlined operations, increased throughput, and improved overall efficiency.
3. Flexibility and Adaptability: One of the standout benefits of Yaskawa Motoman robots is their flexibility and adaptability. With a wide range of models and configurations available, these robots can be tailored to meet the specific needs of diverse CPG manufacturing applications. They can effortlessly handle variations in product sizes, shapes, and packaging requirements, accommodating evolving market demands and enabling rapid product changeovers. This versatility empowers manufacturers to respond quickly to market trends and seize new opportunities.
4. Enhanced Workplace Safety: Creating a safe working environment is a top priority for every manufacturing facility. Yaskawa Motoman robots are equipped with advanced safety features, including collision detection, built-in safety controllers, and collaborative capabilities. By integrating these robots into the production line, manufacturers can minimize the risk of accidents and injuries associated with manual labor. This not only ensures the well-being of the workforce but also helps companies comply with stringent safety regulations.
5. Strong Return on Investment (ROI) and Use Case Examples: Yaskawa Motoman robots offer tangible ROI, making them a wise investment for CPG manufacturers. Some of the strongest use cases with compelling ROI include:

• • Packaging and Palletizing: Yaskawa Motoman robots excel in automating packaging and palletizing processes. By leveraging their speed, precision, and adaptability, manufacturers can significantly increase packaging throughput, reduce labor costs, and improve overall product consistency.
  • Pick and Place: In applications where high-speed, repetitive picking and placing are required, Yaskawa Motoman robots deliver exceptional results. They ensure consistent quality, reduce cycle times, and free up human resources for more complex tasks.
  • Machine Tending: Yaskawa Motoman robots are adept at tending machines, such as CNC machines or injection molding systems. By automating these tasks, manufacturers can improve production uptime, minimize errors, and boost overall equipment efficiency.
  • Quality Control and Inspection: Yaskawa Motoman robots can be equipped with advanced vision systems for quality control and inspection tasks. They can accurately detect defects, measure dimensions, and ensure product compliance, reducing scrap rates and enhancing product quality.

Yaskawa Motoman robots are a game-changer for CPG manufacturers, offering unmatched performance, flexibility, and ROI. By embracing automation and integrating these robots into their production processes, manufacturers can unlock significant efficiency gains, streamline operations, and enhance workplace safety. Whether it’s packaging, palletizing, pick and place, or quality control, Yaskawa Motoman robots are versatile solutions that can elevate productivity and drive business success.

By leveraging Yaskawa Motoman’s capabilities with MEMCO, you can transform your manufacturing operations, gain a competitive edge, and meet the evolving demands of the industry.

If you’re ready to explore the possibilities of integrating Yaskawa Motoman robots into your CPG manufacturing facility or need expert guidance on implementing automation solutions, our team at MEMCO is here to assist you. Contact us today to embark on a journey of increased efficiency, productivity, and success.

We are excited to share valuable insights on advanced SCADA (Supervisory Control and Data Acquisition) solutions and their transformative benefits for CPG manufacturers. Today, we delve into the realm of SCADA’s game-changing potential, offering new horizons for even the most advanced manufacturers in the CPG industry.

Maximizing Operational Efficiency:

Have you explored the untapped potential of advanced SCADA? Beyond its core functions of monitoring and control, this technology holds the key to unlocking unparalleled operational efficiency for manufacturers. By leveraging real-time data acquisition, analysis, and intelligent decision-making capabilities, advanced SCADA streamlines workflows, reduces costly downtime, and eliminates bottlenecks.

Picture a scenario where your production line automatically detects anomalies, triggering automated corrective actions while providing detailed insights for root cause analysis. This level of automation optimizes your team’s focus on strategic initiatives, fostering innovation and driving significant productivity improvements.

Predictive Maintenance Unleashed:

Traditional maintenance practices are reactive and often expensive, but advanced SCADA changes the game entirely. Equipped with machine learning algorithms and predictive analytics, it enables proactive maintenance strategies. By leveraging real-time sensor data, historical patterns, and predictive models, SCADA can detect subtle changes in performance, identify equipment degradation, and predict failures before they occur.

Envision a scenario where SCADA accurately predicts maintenance needs and schedules interventions at optimal times, preventing unexpected breakdowns and maximizing the lifespan of critical assets. This shift from reactive to predictive maintenance not only slashes costs but also significantly boosts uptime while extending the life cycle of essential equipment.

Empowering Operational Agility:

In today’s rapidly evolving business landscape, operational agility is the key to success. And advanced SCADA serves as your secret weapon. With its flexible and scalable architectures, SCADA empowers manufacturers to swiftly adapt to market demands, seamlessly integrate new equipment, and effortlessly respond to process modifications.

Imagine the ease of introducing new product lines, adjusting batch sizes, or implementing process improvements without major downtime or extensive reengineering. Advanced SCADA empowers manufacturers to achieve operational agility, ensuring competitiveness and unlocking new growth opportunities.

Furthermore, when SCADA converges with cutting-edge technologies like AI Vision System-powered co-robots and cloud computing, it revolutionizes remote monitoring, data-driven decision-making, and fosters cross-departmental collaboration.

By embracing advanced SCADA solutions, CPG manufacturers gain a competitive edge in their industry. They witness increased operational efficiency, proactive maintenance strategies, and the ability to swiftly adapt to market dynamics. It’s time to leverage the transformative power of advanced SCADA to drive success in your operations.

Stay tuned for our upcoming blog posts where we will delve deeper into the capabilities and practical implementation of advanced SCADA in the CPG manufacturing domain.

In today’s competitive landscape, ensuring a return on investment (ROI) for Capital Expenditure (CapEx) projects has become a significant challenge. Many projects fail to deliver the expected results, leaving organizations wondering where things went wrong.

In this blog post, we will explore why many CapEx projects fall short and present a framework that can help navigate your organization around some pretty big icebergs with hidden pitfalls and yield better outcomes: taking a Lean manufacturing, kaizen-inspired approach to designing engineered solutions.

So, let’s dive in and uncover the insights that can help drive success with your big CapEx projects

• The Pitfalls of Traditional CapEx Approaches: Traditional CapEx projects often suffer from common pitfalls that hinder their ability to achieve the expected ROI. These include:
  • Inadequate Front-End Planning: Insufficient planning and analysis during the project initiation phase can lead to a lack of clarity regarding objectives, scope, and expected outcomes.
  •  Siloed Decision-Making: CapEx decisions made in isolation, without sufficient cross-functional collaboration and input, may fail to address the broader operational and business needs.
  • Overemphasis on Technology: Placing excessive focus on advanced technology without considering process optimization and employee engagement can lead to underutilization and suboptimal results.

• Embracing Lean Manufacturing Principles: To overcome these challenges, a Lean manufacturing approach can significantly enhance CapEx project success. Here’s why:
  • Holistic Problem-Solving: Lean principles encourage a holistic view of operations, focusing not only on technology but also on process optimization, waste reduction, and continuous improvement. By addressing root causes and streamlining workflows, Lean manufacturing enables efficient and effective utilization of CapEx investments.
  • Kaizen-Inspired Mindset: Embracing a kaizen-inspired mindset promotes a culture of continuous improvement. Engaging employees at all levels to contribute ideas, identify bottlenecks, and implement small, incremental changes fosters ownership and a sense of responsibility, resulting in improved operational performance.
  • Value Stream Analysis: Conducting value stream analyses helps identify areas of waste, such as excessive movement, overproduction, or waiting time. By optimizing these processes and eliminating non-value-added activities, CapEx projects can be aligned with the true needs of the organization, driving higher ROI.
  • Collaborative Design Thinking: Adopting a collaborative approach to CapEx projects can yield remarkable results. Engaging cross-functional teams and stakeholders throughout the design and planning phase ensures that various perspectives are considered. By involving operators, maintenance personnel, engineers, and other relevant parties, you tap into their knowledge and experience, leading to innovative and practical solutions.
  • Leveraging Digitalization: While Lean manufacturing emphasizes process optimization and employee engagement, it does not disregard the importance of technology. By leveraging digital tools, such as data analytics, IoT, and automation, you can amplify the impact of Lean practices. These technologies enable real-time monitoring, predictive maintenance, and data-driven decision-making, improving efficiency and overall performance.

Conclusion: CapEx projects are critical investments that demand a meticulous approach to achieve the desired ROI. By embracing Lean manufacturing principles, fostering a kaizen-inspired mindset, leveraging collaborative design thinking, and incorporating digitalization, you can enhance the success rate of your CapEx projects significantly.

Remember, success lies not only in advanced technology but also in optimizing processes, reducing waste, and engaging employees. By taking a Lean manufacturing approach, you can unlock the true potential of your CapEx investments and drive sustainable growth in your multi-site manufacturing operations.

Let’s embark on this journey of continuous improvement, operational excellence, and exceptional ROI together through MEMCO’s Future Now program.

 

At MEMCO, we take great pride in our commitment to the veteran community, and giving back to society. As the Platinum Sponsor of the QAD Redzone 2nd Annual Charity Golf Tournament, we are delighted to share how our partnership helped raise over $70,000 for the Special Operations Warrior Foundation (SOWF). 

The Special Operations Warrior Foundation is a remarkable organization that provides comprehensive post-secondary educational support to eligible surviving children of fallen Special Operations Personnel and children of all Medal of Honor Recipients. Additionally, the foundation offers immediate financial assistance to severely wounded, ill, and injured Special Operations Personnel. By ensuring educational opportunities “cradle to career,” SOWF plays a vital role in honoring the sacrifice of our nation’s heroes and supporting their families. We are honored to support SOWF’s mission and contribute to their commendable work.

As the Platinum Sponsor of the QAD Redzone 2nd Annual Charity Golf Tournament, we were privileged to collaborate with a dedicated community of individuals and organizations passionate about making a difference. The tournament served as a platform to raise awareness and funds for the Special Operations Warrior Foundation.

The success of the QAD Redzone 2nd Annual Charity Golf Tournament was a testament to the generosity and support of our community. Together, we raised over $70,000 for the Special Operations Warrior Foundation, enabling them to continue their crucial work. This achievement would not have been possible without the enthusiastic participation of golfers, sponsors, and volunteers.

The funds raised will go a long way in providing educational support to the children of fallen Special Operations Personnel, ensuring they receive the opportunities they deserve. Additionally, the Special Operations Warrior Foundation’s immediate financial assistance will aid in the recovery and rehabilitation of severely wounded, ill, and injured Special Operations Personnel, empowering them to rebuild their lives.

We are humbled to have played a significant role in making a positive impact on the lives of these impacted children and their families. Our commitment to supporting the Special Operations Warrior Foundation goes beyond this event, and we will continue to champion their cause through ongoing partnerships and fundraising initiatives.

 

Here’s the summary of the tournament in case you missed it:

https://rzsoftware.com/resource/2nd-annual-qad-redzone-open-charity-golf-tournament/

If you’d like to make a donation to the SOWF, please visit their website:

https://specialops.org/ 

In the fast-paced world of CPG manufacturing, staying ahead of the competition requires innovative solutions and a collaborative approach. At MEMCO, we have developed a groundbreaking program called Future Now that sets us apart from traditional automation and controls engineering firms. By assembling cross-functional teams and adopting a Kaizen methodology, we empower our clients to tackle their apex problems head-on, driving efficiency, reducing costs, and achieving rapid ROI.

At MEMCO, we recognize that solving complex challenges in CPG manufacturing requires a comprehensive and inclusive approach. That’s why our Future Now program begins by assembling a cross-functional team that includes the client’s engineers, mechanics, operations leaders, front-line operators, sanitation team associates, and quality assurance technicians. By bringing together diverse perspectives and expertise, we foster a collaborative environment that is essential for successful problem-solving.

One of the key differentiators of MEMCO’s Future Now program is the utilization of a Kaizen format. In this approach, the client’s cross-functional team collaborates closely with our team of industrial, electrical, mechanical, and automation engineers. By working together, we design a phased automation strategy that is tailored to address the unique needs and challenges of each client while actually solving the root cause to the specific problem identified by the Kaizen team.

Rather than taking an isolated, “whack-a-mole” approach where individual issues are addressed in isolation, our program takes a holistic view. Each phase of automation is strategically planned to complement and build upon the previous phases. This ensures that the automation solutions implemented deliver a clear return on investment (ROI) in two years or less.

MEMCO’s Future Now program is laser-focused on driving efficiency and reducing costs in CPG manufacturing. By involving key stakeholders from different areas of the client’s organization, we gain valuable insights into the challenges they face on a daily basis. This enables us to identify and prioritize opportunities for automation that will have the most significant impact on reducing costs, streamlining operations, and enhancing overall efficiency.

With each phase of the Future Now program, our clients experience a rapid return on investment (ROI) in two years or less. This accelerated timeline is made possible by the careful planning and collaboration of our cross-functional teams and automation experts. Additionally, the phased approach ensures that each automation phase complements the others, creating a comprehensive roadmap for long-term success.

MEMCO’s Future Now program is transforming the CPG manufacturing sector by taking a collaborative, cross-functional approach to automation. By involving diverse stakeholders, implementing a Kaizen format, and delivering rapid ROI, we empower our clients to overcome apex problems and achieve sustainable growth. Experience the future of manufacturing with MEMCO.

Lance Olmsted, CEO announces MEMCO’s Future Now program©

 

 

As baby boomers retire from the manufacturing sector, many leaders are rightly concerned about the lack of skilled workers to fill the void. As temporary labor becomes more expensive and difficult to retain, this scenario has led to an increased appreciation for automation and robotics as tools capable of addressing this issue.

The North American manufacturing sector is facing a unique challenge as a result of the aging baby boomer generation. As this generation moves into retirement, there is growing concern about a noticeable shortage of skilled workers to fill the positions the baby boomers are leaving behind. In fact, by 2030 the last baby boomer will retire and leave a noticeable knowledge and skills gap within the manufacturing sector. Further, it appears that baby boomers are retiring at a faster rate than in years past.

 

 

Automation and robotics will play a central role in the multi-pronged solution to this challenge. Automation and robotics have the potential to improve manufacturing efficiency within the manufacturing sector. Robotics allows for increased accuracy and speed in repetitive tasks, minimizing the risk of human error. This, in turn, leads to reduced product waste and improved product quality. Furthermore, robotics can complete these tasks faster than humans ever could, which is essential when working on tight schedules and deadlines. Another advantage of automation and robotics in the manufacturing sector is the increased safety they provide. Manufacturing can be a dangerous industry, but robots can remove the risk of injury to human workers in several ways. They can complete tasks in dangerous areas or environments, perform repetitive or strenuous tasks, and handle materials that humans may not be able to.

Overall, automation and robotics have proven to be a valuable technology in modern manufacturing. However, they’re not foolproof, and there are challenges associated with them as well. One such challenge in the North American manufacturing industry is the risk of social backlash. Despite the benefits of automation, people are understandably anxious about the potential loss of jobs due to the rise of robots. Another challenge to consider is that the system may be expensive to implement. In light of the pandemic, however, companies are becoming more receptive and open to automation and robotics. Companies are keenly aware of the pandemic’s implications on social distancing protocols and the potential closure of factories. Additionally, ROI projections in the long term are forecasted to reduce expenses with lowered employee turnover, decreased staff compensation claims, and heightened scalability. While automation and robotics certainly have their advantages, it’s important to note that they’re not a one-size-fits-all solution.

Even with increased automation, there will still be a need for skilled workers in the manufacturing sector. With robotics and automation handling the hectic and menial tasks, employees can focus on more complex tasks such as testing, research and development, and innovation-oriented jobs. Skilled workers are vital in the use and maintenance of machinery, ensuring that the systems work as intended efficiently. In conclusion, automation and robotics are necessary to supplement the shortfall left by baby boomers retiring from the CPG manufacturing sector. Robotics complements and augments the workforce, adding to productivity instead of replacing human workers. Additionally, it doesn’t necessarily mean that there needs to be a loss of jobs. Instead, skilled workers can transition into different roles that the automation and robotics cannot perform. Therefore, the present and future of the CPG manufacturing sector lie in the employees’ integration with the emerging technologies rather than pitting the two against each other. With a balanced approach to the adoption of technology and the continued investment in skilled human capital, the industry will remain resilient and competitive for years to come.

Palletizing robots are becoming increasingly popular in the manufacturing industry. They’re highly efficient, save time, and reduce risks associated with lifting heavy loads. However, some people still question whether a palletizing robot program is a sound investment. While the cost of deploying robots can be high, the benefits that come with using them are many and can be a valuable return on investment.

One of the lesser-known benefits of palletizing robots is that they provide flexibility in equipment and production  line layout. Because palletizing robots are so versatile, manufacturers can redesign the process flow by placing the robot in different locations. This flexibility can lead to a more efficient workflow, where the finished goods can be sorted more effectively. A palletizing robot can also handle multiple pallets simultaneously, further improving the efficiency.

Another advantage of palletizing robots is their ability to handle a variety of shapes and sizes of products, making them suitable for virtually any industry. Robots are also equipped with sensors and cameras to detect the exact shape and size of the product, so there’s no need to worry about manual calibration or the need for additional equipment. This application is an unparalleled level of flexibility for a manufacturer because no matter how different the products are, palletizing robots can adjust and function effectively.

Purchasing a palletizing robot can also lead to cost savings in the long term. Though the initial investment can be high, the return on investment is significant. Manual labor creates additional costs, such as payroll taxes, vacation time, health care, benefit packages (we’ll talk about the labor crisis later!) A palletizing robot can work additional hours for extended periods without breaks or accommodation. This cost reduction opportunity is even more evident when considering the robot’s extended lifespan, as labor costs continue to increase with the addition of overtime. Palletizing robots can also help reduce worker-related injuries, which leads to a safer workplace. Repetitive manual labor can cause injuries from chronic overuse, which can lead to an expensive medical cost liability, and decrease worker morale. Palletizing robots can shoulder this burden, allowing workers to focus on tasks that require more human-specific skill sets, such as problem-solving, decision-making, and communicating with other departments to streamline the entire operation.

The use of a palletizing robot can also improve the quality of products, improving customer satisfaction. By replacing manual labor with a robotic solution, the likelihood of human error decreases, leading to a decrease in recalled products. Additionally, robotic solutions can efficiently handle heavy products reducing packaging waste due to breakage or collapsed loads leading to and overall cost savings.

In conclusion, though deploying palletizing robots for manufacturing operations may appear costly, the benefits of utilizing them are apparent. Their flexibility, versatility, ability to handle random product shapes and sizes, cost-effectiveness, and the reduction of workplace injuries are significant benefits of palletizing robots.

If you’re unsure about how to strategically deploy a palletizing robot program with a strong focus on fast ROI, please don’t hesitate to give us a call to learn more about our Future Now Program.