Five Common Challenges and Solutions for Implementing an Integrated System

Integrating various systems within manufacturing—particularly those involving pneumatic conveying, automated packaging, and palletizing—can present unique challenges. Understanding these hurdles and finding thoughtful, practical solutions is critical for streamlining processes, enhancing productivity, and building a winning collaboration between the integrator and the customer.

Like most projects, it’s ideal to have as much knowledge as possible at the beginning of the process so that you can expect challenges rather than be surprised by them.

“A good systems integrator knows what questions to ask that will lead you to the answer,” says Magnum System’s project manager Pat Hammett. “Unless you ask the right questions, they won’t lead you down the right path.”

Pat Hammett and Magnum Systems regional sales manager Nick Basham discuss the main challenges in implementing an integrated system and how to best overcome them, sometimes turning them into mutually beneficial opportunities.

1)      Navigating Change: Encouraging Positive Project Engagement

When faced with a large, proposed change or a significant investment, it’s common for decision-makers to not all be in agreement. Project engagement emphasizes collaboration and enthusiasm for the project, creating a sense of ownership and commitment among stakeholders. When everyone is on board, it paves the way for collaboration and shared vision, allowing the entire team to enjoy a smoother journey.

“System integration is only successful when all the stakeholders come together and agree to what we are doing," Says Hammett.

Sometimes customers are apprehensive about proposed changes, as any smart businessperson might be. Providing solid data that demonstrates the efficiency and reliability of integrated systems can help the customer understand and visualize the system’s value.

“In a system integration-style project, helping make the customer comfortable and confident with the proposed changes can be challenging at times,” says Basham.

This challenge presents an opportunity to give stakeholders a more compelling demonstration of the potential efficiency gains made possible with automation and system integration. Providing concrete data and evidence of process reliability can effectively address doubt and resistance, leading to smoother adoption of new technologies.

2)     Legacy Systems

"Bringing all the controls together in a single package can be a challenge because some customers use legacy systems," Hammett says. “These existing technologies and controls usually require upgrades."

Many manufacturing plants operate with legacy systems that can impact integration efforts. Most typically, systems from multiple manufacturers come together in a patchwork manner over the years, unknowingly creating challenges when it’s time to modernize processes.

Fortunately, there is a solution. The most mutually beneficial way to mitigate this challenge is for integrators like Magnum Systems to work closely with their customers to assess their existing infrastructure and propose gradual upgrades that can facilitate smoother transitions toward a more modern integrated system.

3)     Safety Risks

Adding technologies can come with additional safety risks. This requires understanding the hazards of pneumatic conveying and automation and ensuring the machine design aligns with rigorous safety protocols. Including safety experts early in the process can help identify potential risks and determine the best approaches to lessen the impact.

"A good integrator will design a system with this in mind to safeguard workers and equipment," Hammett adds.

Designing with safety in mind also ensures that safety protocols are considered and applied in all automation processes. By adequately planning for potential risks and implementing strong safety measures, manufacturers can protect their workforce while reaping the benefits of system integration.

4)     Where Will We Put the System?

Stakeholders may not feel they have enough space for an integrated system. Again, early and clear communication with your customer is a great way to resolve any perceived or real space constraints.

To build trust and transparency, good integrators collaborate with customers to assess the space and creatively address how new equipment can be incorporated into existing layouts. Innovative design solutions or restructuring layouts may be necessary to accommodate new systems without compromising workflow.

5)     Learning and Managing the New Normal

We all grow accustomed to our daily processes. But with work processes and software platforms innovating at a rapid clip, today’s workforce is more adept at shifting and learning new methods and procedures.

To help customers adopt integrating systems, it’s essential to reiterate the benefits of the newly integrated automation, including improved efficiencies and optimum production. Connecting with your customers’ employees and providing training on new technologies is a great way to build trust and get staff up to speed in a timely manner. This approach also fosters a culture of being open to innovation.

While integrating systems in manufacturing comes with challenges, there are practical solutions to prevent or overcome them. Manufacturers can successfully implement integrated systems that enhance productivity and operational excellence by encouraging project engagement, addressing legacy infrastructure, prioritizing safety, optimizing system layout, and providing training for the new system.

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