FEATURE | INDUSTRY 4.0
The combination of automation, sensors and IoT support a facility’s entire material handling and storage needs.
and maximising storage capacity are complex endeavours that require thought and consideration.” He believes that too many companies in this space still manage inventory through a manual hand count process. “Their automated counterparts are able to quickly view inventory via dashboards and satisfy audit requests with the click of a mouse.” Manual storage also leads to lost productivity.
“Vast amounts of space are utilised by inefficient, unsafe equipment with large requirements to manoeuvre within the space. Additionally, many don’t take advantage of vertical space effectively. An automated environment not only safely moves product, but it also maximises storage density and at the same time keeps product available for the next stage in the process,” Jackman says. For ABB, Donchev feels that mining companies
are becoming more receptive to the idea of smart hoists. “It’s definitely getting easier,” he says. “A few years ago, conversations around upgrading hoisting systems were more focused on mechanical reliability and throughput. Now, with the rise of Industry 4.0, mining companies are increasingly open to digital solutions, especially when the ROI is clear in terms of safety, reliability and reduced downtime.” The caveat he adds is that there is still a learning curve for the industry. “Concepts like predictive maintenance are gaining traction, but functional safety isn’t always front and centre in mining the way it is in other industries. ABB will often walk customers through how Smart Hoisting can help identify potential safety hazards before they
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escalate, using real-time data and diagnostics. For example, our system automatically monitors brake performance, motor health and drive system behaviour, which can flag issues that might otherwise go unnoticed. “Once teams see how these insights translate
into fewer unplanned stoppages and safer operations, the value becomes more apparent.”
Key benefits On the factory floor or in the warehouse, automated material handling is a key component in intralogistics. This uses a combination of automation, sensors and the Internet of Things (IoT) to tie together a facility’s entire material handling and storage needs. “By having one system orchestrate the movement and storage of products throughout your facility, not only do you have traceability, but you can orchestrate the right product in the right place at the right time in a manner that isn’t possible in a manual operation,” says Jackman. One of the most attractive elements of
automation is reducing costs. Robots never take breaks and can work round the clock, improving throughput. Another big benefit is in safety. “If the material handling is automated there are a lot less safety concerns, because all automation areas should be guarded so no personnel is operating or near moving parts,” says Jackman. “This is great news for the metals industry where unfortunately many of the industry’s fatalities and incidents are associated with material handling, moving vehicles and storage areas.”
While storage is often not a priority for automation, Jackman points out that it is typically the least safe area on customer sites. “Customers are comfortable with A to B movements which are highly repeatable, but it is the less repeatable movements which happen within the less safe areas. Our goal should be to automate the areas which are a concern to put our personnel in harm’s way.” Automation reduces the need for workers in these dense and more dangerous areas of warehouses. “Every way that we can limit personnel having to enter the area is a win for us, so for example Vision is a great tool to allow the system to see the issue and where possible auto recover and continue on.”
More to come Automation is an innovation that will continue disrupting the material handling industry. “We most often think of cranes being automated, but a whole slew of other capabilities that extend all the way to touching the product, metal in our case, are continuing to be developed which make automation even more attractive to companies with a future mindset,” says Jackman. However, we are also starting to see pushback
from unions who see automation as a job stealer. But ABB believes it is about deploying automation in the right way. “The key is thoughtful implementation,” says Donchev. “When automation is used to enhance safety and reliability, it can be a win for both operations and the workforce. It’s not about replacing people; it’s about making their jobs safer and more effective.”
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