This month, we’re looking at the growth of workers 65 or older, who choose to stay on the job. They now make up 22% of all American workers. How does that affect manufacturing and distribution operations? What can you do to accommodate these workers? Also: more on packaging automation, manufacturing in Texas and more.

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Every facility has its heroes like the shiny conveyor systems, towering pallet racks and state-of-the-art automation that seem to draw all the safety focus. But just like in any good action movie, even the heroes have a few weaknesses. Warehouses and manufacturing facilities are no different! These “weak links” are the areas that, if overlooked, can cause big safety issues. You can create a stronger, more resilient facility by paying attention to these sneaky trouble spots.

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Automated palletizing is one of the best places to target automation because the process is so manual and heavy duty for many companies.

Why? Because it helps you reduce one of the least value-add parts of your operation: stacking and creating pallets. Doing that manually makes less sense every passing year for companies that are already working to reduce dependency on an ever-contracting labor pool. To get the process started, start by focusing on your operational needs, customer base and labor factors.

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In the cold and frozen food sector, tremendous growth combined with a serious shortage of capacity is severely constraining companies today. “The frozen food market is currently experiencing remarkable growth, with its global value soaring to $265 billion. In the U.S. alone, new frozen food sales have impressively surpassed the $72 billion mark,” states Rick Kingery in the Colliers’ article “Capitalizing on the $265 Billion Frozen Food Market: Cold Storage’s Crucial Role.”

Adding to the challenge, “We estimate the U.S. will need up to 100-million-square-feet of additional cold storage space in the coming years,” states Marty Khait in an article posted on the Refrigerated & Frozen Foods Magazine website, “The Cold Reality: Why America’s Cold Storage Capacity is Running Low.”

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You’ve seen the statistics about labor shortages over the last few years. The reality for recruiters on the ground is more obvious: there have been plenty of no-shows for job interviews (or for the first day of work). Candidates ghost companies throughout the process. You may have to take down a job posting only to put it right back up when someone quits. Particularly for the roles warehousing and manufacturing companies need to hire, the difficulties are real – and only growing.

So how do you attract and keep the right candidates for your company?

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Your pallet flow system produces a smooth, orderly process first-in, first out product flow. To ensure it performs, regular inspections and timely repairs are essential. Although pallet flow systems typically require minimal maintenance, proper employee training and consistent checks can help avoid misuse and prolong the life of your equipment. Pallet flow systems are built to flow heavy pallets from infeed to picking, using brakes and dampeners. Over time, these components must be inspected, maintained or even replaced for optimum, safe performance.

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Initiating an automation project can be daunting. You have to ask for a budget. You have to justify your ideas. Inertia and tradition are your enemies. If you find yourself staring at a blank page, intimidated by the idea of beginning to automate, you’re not alone.

As we have discussed before, there’s no reason you must automate all at once when incremental steps will serve. You can set yourself up for success and start a project with greater confidence with careful thought and planning. What does that process look like?

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Conveyors are the beating heart of any industrial or distribution facility. Their daily operation is critical for moving product through your facility and to the key functional areas. They must flow seamlessly, each one performing its task to move forward.

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This month’s Insights focuses on top states for new factories, autonomous technology and the latest on manufacturing workforce development.

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If your operation is mature, up-and-running, and delivering results, is it possible to automate individual steps and achieve excellent ROI? The answer is yes — but only in cases where your process is well-defined and correctly segmented into steps you can analyze for productivity gains. This kind of localized productivity is often the intersection of productivity and automation.

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