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End-of-line Specialist Moves Toward Condition Monitoring

Fallas Automation places an even greater emphasis on integrating early warning systems for predictive maintenance since COVID-19 set in.

Oan Fallas Speedybot

Fallas Automation is a well-known producer of end-of-line packaging equipment, case packers in particular. Its machine designers have been aware for some time that customers today are struggling to find and retain personnel technically qualified to operate and maintain complex packaging machinery. So a key goal has been to design Fallas end-of-line packaging machines so that they are easier and less technical to operate and troubleshoot.

“We also want plant management to have real-time access to machine information and to increase Fallas’s role in predictive analytics,” says Dan Maeyaert, Vice President of Manufacturing Operations. Echoing him is Jacob Cox, Vice President of Electrical Controls: “There are many things that we can do to improve the operation of our end-of-line machines without having to jump across a wide technology gap. Everyone would have been much further along if we had had these early warning and simple-to-operate systems in place before the pandemic. There would have been a far higher assurance of faster issue resolution, especially during the lockdowns that limited travel and entry into plants. Machines that are easier to operate could mean fewer people in the plant and increased flexibility in assigning staff.”

Oan Fallas Festo PicFallas was able to complete a number of installations during the pandemic without needing to send a tech into the plant. Phone support, obviously, played a key role. “But we also heavily prepared the customer with videos and pre-training on what to expect during installation,” says Maeyaert. “We also, on occasion, used augmented reality apps and video calling to aid in clarifying some problem areas. Because of the prep and phone assistance we were able to complete installs and start-ups with no on-site techs, saving time and money for our customers.”

Videos from Fallas Automation Inc.
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