Safe, Efficient, Profitable: A Worker Safety Podcast
Joe and Jen Allen of Allen Safety LLC take their combined 40+ years of worker safety, OSHA, EPA, production, sanitation, and engineering experience in Manufacturing Plants including Harvest Plants/Packers, Case Readies and Further Processing Plants, Food Production Plants, Feed Mills, Grain Elevators, Bakeries, Farms, Feed Lots, and Petro-Chemical and bring you their top methods for identifying risk, preventing injuries, conquering the workload, auditing, managing emergencies and catastrophic events, and working through OSHA citations. They're breaking down real safety opportunities, safety citations, and emergency situations from real locations, and discussing realistic solutions that can actually be implement based on their personal experiences spending 40+ weeks in the field every year since 2001. Joe and Jen are using all of that experience to provide a fresh outlook on worker safety by providing honest, (no sponsors here!) and straight forward, easy to understand safety coaching with actionable guidance to move your safety program forward in a way that provides tangible results.
Safe, Efficient, Profitable: A Worker Safety Podcast
#40: Top Questions to Ask Before Installing Robots
Summary:
In this thought-provoking episode, hosts Joe and Jen dive deep into the pivotal question of whether investing in robotics for your industrial plant is a strategic move for the future. With industries facing a significant labor shortage, the demand for automated solutions has surged. The hosts explore the multifaceted impact of AI and robotics on safety, knowledge retention, and procedure updates for new hires. They also address challenges such as equipment setup and early shift operations, emphasizing the potential for robotics to revolutionize safety measures. Tune in for invaluable insights into navigating the dynamic landscape of automation in the workforce and making informed decisions for the future of your plant.
Episode Description:
The conversation unfolds with a candid discussion about the far-reaching implications of incorporating robots into the workforce. From revolutionizing production efficiency to mitigating labor shortages, the hosts provide keen insights into the advantages that these technological advancements bring to the table. They delve into the intricate dance between human workers and automated systems, highlighting the crucial role played by knowledge retention and transfer in this dynamic environment.
One of the most pressing challenges discussed is the need for robust procedures in automated settings. As new hires step into roles traditionally managed by experienced personnel, the hosts emphasize the necessity of comprehensive training and updated protocols. They explore how procedure updates can bridge the gap between legacy knowledge and emerging technological landscapes, ensuring seamless operations in an increasingly automated world.
The conversation pivots to the critical juncture of equipment setup, an early morning endeavor fraught with risks and stress. Joe and Jen articulate the pivotal role that automation can play in minimizing hazards, enhancing efficiency, and streamlining operations. They highlight the potential for robotics to revolutionize safety measures, particularly in high-risk and ergonomic-intensive tasks.
Ergonomics and injury prevention in robot-driven environments emerge as focal points of discussion. The hosts delve into the transformative impact of automated systems on workplace safety, offering actionable insights for plant managers keen on minimizing risks. They emphasize the potential for robotics to not only bolster productivity but also create safer, more sustainable working environments for employees.
The episode culminates in a thoughtful exploration of return on investment (ROI) considerations for robotic investments in manufacturing. Joe and Jen unpack the various factors that plant managers should weigh, including initial capital outlay, ongoing maintenance costs, and the potential long-term benefits of streamlined operations. By providing a comprehensive framework for evaluating the ROI of robotics, they empower listeners to make informed, strategic decisions about the future of their plants.
Robot safety in industrial plants
Labor shortage solutions in manufacturing
AI and robotics impact on workplace safety
Knowledge transfer in automated environments
Procedure updates for new hires in automated settings
Equipment setup safety measures
Early shift challenges in manufacturing
Ergonomics in robot-driven environments
Injury prevention in automated plants
ROI for robotic investments in manufacturing
Workplace automation and safety measures
Industrial robotics and safety protocols
Safe practices in automated manufacturing
Worker safety in high-tech manufacturing
Safety considerations for automated equipment
Hazard mitigation in robot-driven plants
Plant safety in the age of automation
Risk assessment for robotic investments
Safety measures for automated production lines
Ergonomic considerations in automated industries
This week's episode. Should you buy a robot for your plant, for your company? I don't know.
Speaker 2:I don't know either.
Speaker 1:That's what we're going to talk about this week Positive and why you may actually want to buy one. All right here we go.
Speaker 2:Let's go.
Speaker 1:All right, here we go.
Speaker 2:Here we go.
Speaker 1:Who doesn't love robots? My son loves them. We got one of those vacuum things that runs around the house and he spends most of his day trying to stop it, turn it off, break it down, clean it and never put it back together.
Speaker 2:Yeah, that's part of the reason why we're we thought about this today, because they're kind of taking over everything and we had an amazing listener request that was like hey, can you talk about it. Can you talk about safety and the path of AI and robots and how you think all of that ties together?
Speaker 1:So we're doing it. We're doing it. So the first one is should you even buy one? That's the question everybody asks. Everywhere we go, everybody's looking to buy one. This is a podcast. Can't get to everywhere and you can't travel every week, so what do you do? Robot systems systems, computers systems, robots, whatever that is.
Speaker 2:Well, I know that that's one of the biggest driving factors that people are having right now, because they're short on labor and the demand hasn't gone down. So how do we fill the gaps?
Speaker 1:of that.
Speaker 2:What do we do? How do we meet the customer demand? How do we make sure that we're staying within that price point, because that's big too.
Speaker 1:So the beginning of this episode is talking about some opportunities. The end of the episode is talking about some conclusions, ideas, concepts, how to fix them up.
Speaker 2:Here we go.
Speaker 1:So labor issues is one of them. One of the weirdest things that came out of it was experienced people that were great at doing the task left during the pandemic. We did not onboard the next group, we did not train the next group, we just left.
Speaker 2:Well, we didn't think they were leaving. That was part of it, so the succession planning was kind of limited.
Speaker 1:It didn't even take place in some so then you got a job that the person was kind of in a weird way, the control that managed everything, the stuff that was on paper and really not. And then what happened is when they left, now that knowledge is gone and the time you can't get all those years back of knowledge. So you're looking at how do you get the time back?
Speaker 2:Yeah, there was a lot of data that we had. That was kind of implied.
Speaker 1:Right.
Speaker 2:Just that you gathered over your experience working in the field, working at that plant in particular, maybe working with that specific machine. Maybe sometimes it's a little touchy, so you've got to do these five things or something. We lost all of that and it wasn't captured in our procedures.
Speaker 1:So now the person Joe's a new hire, joe's a new hire didn't get the same onboarding, didn't get the same train, didn't get those little things you talk about or there that they do. So the system doesn't run right. So the product per minute or the response or the downtime is all off now than what it was.
Speaker 1:We're slowing down line speeds and some circumstances Because that person used to know if you do this real quick, it puts it back in operation, and now we don't have that. So what's happening is that the time has increased dramatically. If something goes wrong, yeah, and now you're looking at okay, if we bought a robot to do that problem, then all we're managing is the robot and that doesn't retire and doesn't leave on us.
Speaker 2:So that's where some of the thoughts are coming from and, honestly, from a shift standpoint, we're having a little bit of difficulty hiring for the offshifts. A robot runs 24 hours a day, if we wanted to.
Speaker 1:Those of you don't know us that much. We're Joe and Jim. We work in the meat industry and one of the things that everybody talks about is the price of meat is whatever I'm like. You know that labor is not full and the lines aren't full and full staff yet, but they were six years ago. So if there's nobody to process the product, then there's no product. So part of that is how do we do that for the consumer? How do we do that for the industry of the world? You may have to look at getting a robot to bring those timelines back down so that so the specialty cuts or the specialty projects may be a human, but the, but the putting a box somewhere, doing something that would have normally been a human, going left or right or right. Maybe that's a robot now, because that gets your time back for labor.
Speaker 2:Well, and when you have limited staffing, you know you're going to fill the probably least impact from an ergonomic standpoint. Job first, Correct. So when you think of boxing and palatizing, I mean those were always big ergo jobs and so we have the opportunity to say, hey, could we have a robot? Step in it Because they make them, Because we're short-handed and they make them and they do it.
Speaker 1:And for those of you people who don't know much about us, we used to go overseas a lot and one of the things we did we did work for companies that helped build robots and we got to talk to them a lot like a whole bunch of weeks during the year about what they're doing and why they're doing and what they're doing, how the world's looking and a lot of it is is that here in the States our systems are very reliant on the people's and the concept, the way they do it.
Speaker 1:Where in other countries, or some of the crews we worked with, very much was mechanical and how the robot or how the computer system worked and interfaced with the piece of equipment. Their knowledge was on that. If you told them, hey, how do you run the production line or cut a piece of meat, they'd be like I'm not sure, but they can sure tell you how to wire that device and make whatever it is, do what you want it to do. So that's kind of. By the way, for those who don't know, I am wearing the American Flag stuff. We do have the Navy Corning Cup up, because it is Veterans Week coming up this week.
Speaker 1:Yeah, happy Veterans Day to all my veterans out there, that's awesome, yes, and, by the way, you know it's the right cup because you don't drink. There's only certain coffee cups. They kind of drink up as well. Yeah, anyway, so the point of it is thank you for everybody out there who served any time. It doesn't matter when you did, but I appreciate it so it's kind of cool.
Speaker 1:All right, so that's the first one. So now the next thing we're looking at is a Monday morning. Monday morning we're getting ready to set up the equipment. I've got six people scheduled to set up the equipment to show up. So now I am having 100 people stand around with nothing really to do because until the equipment's set up then no one else can do their job because the equipment's not set up. So now the two people are stressed or freaked out. So from a safety side that's a lot of risk and stress those people. The first thing in the morning first waking up, first going in and then like or even third shifts just trying to finish. But the first shift was just to come in and help, but they never showed up. So now third, staying tired, trying to fix the equipment, get it going.
Speaker 2:Well, and that's part of it, and the other part that kind of also goes with that is that some of these jobs because of the weight of the equipment or where you're having to move it, and how you get it in place. It wasn't a one-person job. It was a two or three-person job. Well, if you don't have the labor to do some of that now, you're having a problem.
Speaker 1:Well, again you're gonna grab the person next to you who's never done it in the life and say when you want help, so from a we're safety companies. So for the risk standpoint, that risk variable has went up dramatically.
Speaker 2:It's going crazy right now.
Speaker 1:For the one-offs like that. But it's real, it's not one-off anymore. Six years ago we would have said that's hardly ever gonna happen. Now we're like, okay, that happens.
Speaker 2:Yeah, I feel like we're running during deer season all the time which is coming up right now too.
Speaker 1:Anybody knows our industry, that means.
Speaker 2:You knew people weren't showing up when it was deer season. It was just a given and I feel like we're running like that all the time and it's like are they gonna come today? I don't know.
Speaker 1:So that's kind of a wrap. So now we're at first the experience people are gone.
Speaker 2:A little bit. Yeah, we've lost experience.
Speaker 1:And now we've got some people that don't show up for whatever reason. For whatever reason, and as you have that now, now you have the risk of I don't know the equipment. Maybe I gotta set the coat to my left. I'm not really good at that. I always do these five. Now I've gotta do these three to my left, but I'm not really good at so your risk as the safety side goes up. The procedures were always wrote. I can. Late in the experience person was kind of putting stuff together. Now you've gotta rewrite procedures to capture how you would do it if you didn't know. And so when you review your procedure, review your concert, review your annual trainer, annual, whatever it is, lockout, whatever you gotta back up now and say, okay, we need to look at how it would work if I had to do it and I have no clue how to do it.
Speaker 2:Cause that's where I look at it we're changing the amount of information we're having to include in those procedures, which really makes it critical who is writing those.
Speaker 1:Right, so now we go back to. By the way, we have a legal disclaimer. This stuff is our opinion.
Speaker 2:It's our opinion do a thorough risk evaluation, because every situation is different. While a lot of plants have similar things going on, every circumstance is a little different, so don't just implement across the board. Do an evaluation first.
Speaker 1:So we go back to now. Now the procedures. Now the procedures are constant. They were absolute. They're flawless. Maintenance person one reviewed them. They're perfect. Maintenance person one said yes, to write Now that procedure may not be right. Now that procedure could have a one-all. Now that procedure I've got to have every little. Now I may have to have a setup step and a breakdown step and a cleaning step and a and a these Troubleshooting step.
Speaker 1:PM, step Right and stuff. I would have just. You know, joe would have just done it because that's the way you do it and our review procedure says fine, but now I've got to go back and add all that stuff now and that's it. Because who?
Speaker 2:Well, and that's the other-, Because the person that knew it isn't there. No one, yeah. So who is the person that's editing the procedures? For some of this equipment too? And the positive thing on the robot side is that you've got the text and the installers that can help you do some of that.
Speaker 1:Yes, you have a reference and you have things that are programmed. Yeah, you have a reference. And certain specific programs you can run to do some of these things and some programs you can't run on purpose.
Speaker 2:Yeah, so when you just have a piece of equipment that's not robot driven, you don't have some of that.
Speaker 1:Correct. And when you take computer screens or you take any kind of machine where you've got, this computer does this and this one interface, this, this one does this process. A lot of those are set up that if you're right, if you had a fail, you call a number and they can literally talk you through because it's a computer program.
Speaker 1:Well, now that's different, where if you didn't have a machine that had that technology nowadays, if you had an older machine you're really going back to. For those of you who don't know, I can't change oil in a vehicle. I'm glad there's people to do, because I pull in and it takes them 15 minutes and I'm on, but I couldn't do that. So it's the same concept. There's skill sets that people have or don't have. Over time we lost those skill sets, we lost that idea, and now the labor happens where they're not all there. Now it's almost easier to call the one in her number and say, hey, how do I reporgant? And some of those, some people can do it remotely.
Speaker 2:They can repost some of the systems remotely. Yes, some of them can be done remotely, and then some of them will come and travel to you. So if you are having staffing shortages and you don't have people that can do that, they bring in crews to do it, correct which we used to train a bunch of those.
Speaker 1:We'd come from different parts of the world and we'd come to states and we'd meet them at different places and we'd work on what do you do when you come to states and how the problems and things we're facing. And they would, they would literally come in, some of them would say for months and just go plant to plant.
Speaker 1:So, yes, so the robot is more than just the robot. The robot is it's a downtime issue, it's maybe a labor issue, it's a knowledge issue, it's a show up on Monday morning issue. And then again, now you've got some support and some ideas to maybe help you and you're not getting that with somebody else. So, if you look at your systems, like I said, we have podcasts. Now that's our robots, that's our way that we're getting data out there to people and doing our process, because the world's not moving like it was.
Speaker 2:Yeah. So for those of you who don't know, and because we don't have any sponsors, AlanSafetyCoachingcom is our sponsor.
Speaker 1:That's it.
Speaker 2:that's all I want to say you want some more in depth, where we really drill down into some of these topics. Alansafetycoachingcom is where you'll find that.
Speaker 1:Absolutely, but even that was a necessity out of what happened last year. Yeah, limited labor we couldn't be everywhere and we had more questions and more need than we had the ability to go and physically show up and help.
Speaker 2:So we created a system to do that.
Speaker 1:And we've done the same thing. We've started doing. There's a, if you ever turn the camera that way, there's a big screen over there and we've started doing Virtual coaching.
Speaker 1:Virtual coaching. We had to because the people would say well, I was talking to plant three days ago and they said you know, the person who always validates all these doesn't work here no more. Well, I may be validating them with them, live from the location, because I can at least do that on a screen and work with them. I can't get them, at least I can work with them. That's still a robot.
Speaker 2:Yeah, it's still the concept of bringing in that concept of bringing that robot, using some of the AI, using some of the technology that's at our disposal, to FaceTime when we're on a plant floor doing something. We've done that during leaks.
Speaker 1:Yeah, we have chemical leaks week FaceTime, because that's the technology.
Speaker 2:I can't physically get there before it's over.
Speaker 1:Alright, so the last one is here and will be done. Here is the you. Just you got to remember. The positive thing about a robot, too, is look what that thing can do and how great and big it is. So you got to. But what you got to do is you got to go back and look at back to ergonomics or ergonomics. Look at where you can get a not just a payback on labor, where you get a payback on injury reduction.
Speaker 1:Yeah we can get a payback on reducing that, that setup risk, or reduce those set up, whatever the hazard is. So do like a matrix and figure out here's my jobs, that here's where I think I need one, and then that's how you do these jobs.
Speaker 2:You know some of the jobs are not everyone's favorite absolutely to do so either because it's a dirtier job or it's an ergo job or whatever that looks like, and then you can kind of look at can I even feel these first, second, are they an ergo risk? And then it kind of evaluate what's my return on investment.
Speaker 1:Absolutely. For those you don't know about my history, my very first food plant was almost 100% robot driven. It was wild to watch how the robot would dump the product and then mix a product and the package of product and palletize a product. And I was just amazed because it was in town I grew up in. So that's kind of cool that I'm like here, I am in the town I grew up.
Speaker 2:I didn't even know this, yeah.
Speaker 1:I didn't know this world existed, but it was wild to see how it could interface, how it can move it. But that was my first. Suppose I've looked at that world differently ever since then because that was so wild to me that what we could or couldn't do yeah. And that was, you know, 30 years ago almost.
Speaker 2:Yeah, so I think that that would be my biggest thing is that for those jobs that you're having trouble filling are historically high risk for my ergo or safety safety.
Speaker 1:Absolutely.
Speaker 2:You know what's it going to take to get the return on the investment and what does that initial investment look like, and then what does the support to maintain it look like, and then you can kind of calculate. Does it make sense for you?
Speaker 1:Absolutely so. That's our, that's our addition today. Yep, jen Joe robots, don't forget all your veterans out there. All right, everybody.
Speaker 2:Thanks for tuning in and we'll see you next week.
Speaker 1:Thank you.
Speaker 2:Thank you for listening to Safe, efficient, profitable a Worker Safety Podcast. If you're looking for more in-depth discussions or step-by-step solutions on all of the different safety and regulatory topics, please visit us at wwwallonsafetycoachingcom for web-based virtual coaching and training, or at wwwallondashsafetycom to book our team for on-site services, training sessions, to order merchandise, to learn more about our team and what services we provide in the field, or just simply to request a topic for us to cover on our next podcast. If you found today's podcast helpful and would like to support our podcast further, please help us by subscribing, liking and sharing this podcast with anyone that could benefit from the information we cover here, as that helps us to continue to put out this free content. Thank you so much for your support. Music you.
