Ready for an Upgrade? Here's What to Consider When Upgrading Legacy Equipment and Embracing Advanced Manufacturing

Over the last few years, advances in technology (IIOT, Robotics, etc.) have allowed companies to bring new equipment and efficiency to industrial applications, driving advanced manufacturing. There are many benefits to advancing your manufacturing operations and processes. Increased productivity/efficiency is typically the driving factor when considering an upgrade to your facilities’ equipment, safety however should also be at the forefront of any upgrade. Many factories are filled with high-risk legacy equipment that has them operating at a competitive disadvantage to their competitors. The question facing manufacturers is not do I upgrade, as there is a competitive impetus to push your organization to modernization, and the realities of our post-pandemic world, but whether to buy new equipment or optimize the existing legacy equipment. 

Since there’s no singular approach that will fit every scenario, it is important to consider the pros and cons of modernization options. While the most straightforward would be to purchase new IIOT ready equipment, the truth is it can be expensive and without fully considering the needs of your business, it could be added cost with little upfront ROI. Thus, to maximize success, keep your engineering teams part of your discovery phase.

 Aside from the improved energy efficiency, lower costs of operation, and improved reliability, IIOT enabled equipment may help facilities improve worker safety through smart engineering protections or removing hazards altogether.

For many factories, optimizing the equipment to ensure the safety of your employees is key.

 Operations and line managers should perform a safety risk assessment on all machinery to determine where upgrades may best be implemented before construction on your new system begins. A thorough risk assessment will allow operators to identify potential machine hazards and implement automated controls that keep workers safe and production lines moving. Once the initial assessments are complete, operators should look to turn-key providers should they not have the onsite EHS personnel to guide them through the buildout of a modernization project. This eliminates the need for coordination between multiple vendors, which can lead to project delays, cost overruns, and incomplete solutions.

At the Plus Group, we create solutions for the specific needs of your modernization plans. From Packaging to Automation to IT Services, we're a turn-key solutions partner that can help you manage a machine upgrade project from start to finish helping you to maximize your ROI from the beginning with safety in mind. Industry 4.0 is already here, we're here to help you make the most of it.