Predictive Maintenance in Manufacturing: What, Why, and How?

PREDICTIVE MAINTENANCE IN MANUFACTURING
Predictive maintenance analytics is a type of maintenance that frequently monitors an asset's health. This timely maintenance or monitoring of assets or machines reduces unexpected breakdowns and allows manufacturers to plan around their production schedule.

“Even the best-built machines need proper preventive maintenance to remain productive and reach their maximum working life.”

- PMI (PREVENTATIVE MAINTENANCE INSPECTION) 

Predictive maintenance methods and software have evolved. Companies no longer need to import data into spreadsheets and extract insights manually. Businesses can now effectively estimate maintenance tasks using AI and machine learning algorithms in predictive maintenance systems. Robots and Internet of Things (IoT) devices are also generating more data than ever before, helping manufacturers be more insightful in their operations and processes.


Why Should Predictive Maintenance Manufacturing Be Considered?

The depreciation cost is significant in industries like manufacturing, where the cost of advanced equipment is very high. This makes it important to make sure that the assets of the manufacturing company are well-managed.

Using the predictive maintenance model in these situations saves money on multiple levels. Even though there are protocols like lean management and six-sigma, their usefulness is being questioned when it comes to existing business practices.

In a world where technology dictates practically every aspect of our lives, it is essential to have efficient procedures powered by cutting-edge technology. In essence, predictive maintenance aims to upgrade asset management using IoT.

According to a PwC analysis, manufacturing predictive maintenance
  • Cuts cost by 12%
  • Increases uptime by 9%
  • Extends the life of old assets by 20%
  • Reduces safety, environmental, quality, and health hazards by up to 14%


Types of Predictive Maintenance Technologies

 
 
Vibrational Analysis Acoustical Analysis (sonic) Acoustical Analysis (ultrasonic) Infrared Analysis
This is the preferred method for predictive maintenance in high-rotational industrial plants.

It is cheaper than other condition monitoring methods because it has been around longer.

Vibrational analysis can detect imbalance, misalignment, and bearing wear in addition to looseness.
This form of analysis is employed for low-and high-rotating machines. It's popular among lubrication technicians.

However, it does not focus on identifying the reasons for rotating equipment failure by measuring and recording vibrations at discrete frequencies for trending purposes.

Instead, acoustic bearing analysis targets lubrication technicians and focuses on proactive lubrication.
Ultrasonic acoustical analysis is solely used for predictive maintenance.

Its ultrasonic detection capability can distinguish between ultrasonic noises of machine friction and stress.

This form of analysis is more accurate than vibration or oil analysis.
This form of analysis is not affected by an asset’s rotational speed or volume. As a result, it is ideal for a wide variety of asset types.

When the temperature is a good indicator of possible problems, infrared analysis is the most cost-effective way to keep things running smoothly before they break down.

It is frequently used to diagnose cooling, airflow, and even motor stress issues.


How to Apply Predictive Maintenance Analytics in Practice?

Management is supplied with ROI scenarios prior to implementing predictive maintenance on the factory floor. Additionally, maintenance personnel and machine operators require training on how to use PdM technology (predictive maintenance). Following this, the true implementation of predictive maintenance equipment begins.


Establish Benchmarks

The maintenance team establishes acceptable condition thresholds for sensor-equipped assets.


Connect Gadgets to the Internet of Things (IoT)

The sensor is attached to the asset. A vibration meter, for example, is attached to a mechanical asset through gears, while a temperature sensor is attached to a boiler.


Integrate Hardware and Software

In this case, the IoT device is connected to a central management system (CMMS) or a remote dashboard, which collects and analyzes data.


Establish a Maintenance Schedule

Inspections are initiated automatically by a CMMS when a condition limit is exceeded or manually by the person monitoring the dashboard.


Predictive Maintenance Example


Preventing Power Outages

Power outages can be extremely inconvenient for those affected. They can be discovered early and so avoided with predictive maintenance technologies. Sensors would once again be used in this situation to deliver artificial intelligence-based insight into assets. This intelligence-based insight alerts the plant supervisor when equipment is about to malfunction.


Manufacturing Supervision

Since industrial plants typically contain many expensive assets and valuable equipment, they may invest in infrared imagers to monitor various elements of assets, such as temperature, to avoid overheating. This predictive maintenance technology assists plants in avoiding excessive use of critical equipment, which might result in disruptive breakdowns.


Final Word

Predictive maintenance is an advantageous tool for larger organizations that have outgrown typical preventative maintenance approaches and have an additional budget. It can generate a positive return on investment, transforming the maintenance department into a source of cost savings and increased revenues.

Predictive maintenance has some drawbacks, such as high startup costs and the requirement for specialized expertise. However, it helps to conduct maintenance only when necessary, assisting facilities in cutting costs, saving time, and maximizing resources.

Consultation with equipment makers and experts in condition monitoring should be conducted prior to determining whether predictive maintenance is the best approach for specific assets.


FAQ


Is predictive maintenance cost-effective?

Yes. Predictive maintenance saves between 8% and 12% compared to preventive maintenance and up to 40% compared to reactive maintenance, according to the U.S. Department of Energy. 


What is the difference between predictive and preventive maintenance?

Predictive maintenance saves money on labor and materials, whereas preventive maintenance is less expensive to undertake. Moreover, preventive maintenance is scheduled on a regular basis, whereas predictive maintenance is scheduled on an as-needed basis, depending on asset conditions.


What is TPM?

TPM, i.e., Total Productive Maintenance is a team-based method that focuses on proactive and preventative techniques to increase plant and equipment reliability.

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Prolec GE

Prolec GE, headquartered in Monterrey, Mexico, is dedicated to designing, manufacturing, and selling products and solutions for the generation, transmission, and distribution of electrical energy.

OTHER ARTICLES
Digital Transformation

Digital Twin in Manufacturing: Helping Businesses in Growing Their Revenue

Article | April 1, 2022

Digital twin technology in the manufacturing industry is playing a vital role in evaluating current and future production line conditions to increase OEE, productivity, and business profitability. It has become the most critical component of industry 4.0 because it collects precise data about your manufacturing process and uses that data to help you make wiser decisions. In other words, manufacturers can utilize digital twins to check and assess physical assets, processes, and systems in a virtual environment. In this article, we will discuss some of the major applications of digital twin technology in the manufacturing industry. Additionally, we also have a look at how this technology helps businesses increase their ROI. Digital Twin Technology Applications Product Development Product development is a long and intricate process. For example, it might take up to six years to develop and launch a new automobile model. The shift from the previous model to the new model must be seamless. A minor error during this process might have a detrimental effect on the brand's value and revenue. A digital twin software enables the integration of data between previous-generation models and the new concept's digital representations. Additionally, twinning facilitates communication between product designers, end users, and other stakeholders. When it comes to product testing, having digital twin platforms eliminates the need to wait for performance data from car trials to determine the product's performance and quality. Design Customization As consumers become more intelligent, and demand personalized items in a timely manner, the manufacturing industry will become increasingly competitive. According to an Industry Week Special Research Report on the future of manufacturing, industrial enterprises of all sizes place a premium on process improvement and customer relationship strengthening, while small businesses focus on addressing customer demand for product customization. To assist in the customization process, manufacturers use Twin Design Customization, which enables the virtual design and re-design of goods prior to generating a physical product that fully meets consumer specifications. Shop Floor Performance Improvement The shop-floor digital twin concept helps businesses to be proactive as the system is capable of identifying anomalous situations. This demands attention and process improvements prior to them escalating into a real problem or standstill. Predictive Maintenance Individual digital twin examples for equipment or manufacturing processes can detect deviations that indicate the need for preventative repairs or maintenance prior to the occurrence of a serious problem. Additionally, they can aid in the optimization of load levels, tool calibration, and cycle times. Can Digital Twin Boost Business Revenue? According to a recent study by Juniper Research, revenue from digital twins (a virtual representation of a connected physical product, process, or service throughout its lifecycle) will reach $13 billion by 2023. This is an increase from an estimated $9.8 billion in 2019, representing an average annual growth rate of 35%. The study also discovered that increased deployments of advanced sensors for data collection and technological advancements such as machine learning, artificial intelligence, and high-performance computing are enhancing the benefits of digital twins. So, how does a digital twin help your company's ROI? The digital twin improves transformation efficiency by providing platforms and technologies that simulate the impact of process changes in your supply chain – in a safe, secure, and digitally isolated environment – using real-time scenario modeling generated parallel with live supply chain operations. More than a visualization, a digital twin can help accelerate innovation, foster consensus, and save time and money by iteratively modeling changes, testing how components or systems operate, and inexpensively troubleshooting malfunctions in a virtual world. Final Words The digital twin platforms benefit manufacturing organizations across all verticals, including supply chain management, manufacturing operations, and logistics. Thus, technology is accelerating and enhancing the manufacturing industry to obtain more positive results and, in turn, increase its efficiency and, as a result, its return on investment. The digital twin will gain popularity as businesses learn to use it to their advantage. According to a 2020 analysis conducted by Research and Markets, up to 89% of all IoT platforms will incorporate digital twins by 2025. Thus, the future of digital twins is bright, and we may witness increased use of digital twins in the next few years. FAQ How digital twin help businesses? Digital twins can help businesses make better data-driven decisions. Businesses utilize digital twins to understand the state of physical assets, respond to changes, optimize operations, and add value to systems. How does digital twin save money? A digital twin can save time and money by iteratively modeling modifications, testing component or system functionality, and resolving faults in virtual reality. What are the essential components of digital twin technology? The concept of the digital twin is composed of three unique components: the physical product, the digital or virtual product, and the linkages between the two.

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Manufacturing Technology

Which Additive Manufacturing Process Is Right for You?

Article | December 6, 2021

Additive Manufacturing (AM) uses computer-aided design (CAD) or 3D object scanners to create accurate geometric features. In contrast to traditional manufacturing, which frequently involves milling or other processes to eliminate superfluous material, these are produced layer by layer, as with a 3D printing process. The global additive manufacturing market is expected to grow at a 14.42 percent annual rate from USD 9.52 billion in 2020 to USD 27.91 billion in 2028, according to reports and data. Overall, the worldwide 3D printing industry is gaining traction due to various reasons, some of which are listed below. Significantly, greater resolution Reduced manufacturing costs as a result of recent technology breakthroughs Ease of creating customised goods Increasing possibilities for printing with diverse materials Funding by the government for 3D printing ventures Additive manufacturing is available or may be implemented in various procedures, which is the primary objective of this article. First, we'll look at the seven additive manufacturing processes and which one is the best to use. So let us begin. “Don’t be afraid to go outside of your industry to learn best practices. There might be something that surprises you or inspires you to try in your line of work.” – Emily Desimone, Director of Global Marketing at SLM Solutions Additive Manufacturing Processes There are numerous diverse additive manufacturing processes, each with its own set of standards. Here are the seven additive manufacturing procedures that many manufacturers consider based on their benefits from each process, or whichever approach best suits their product requirements. Material Jetting This additive manufacturing process is quite similar to that of conventional inkjet printers, in which material droplets are selectively placed layer by layer to build a three-dimensional object. After completing a layer, it is cured with UV radiation. VAT Photo Polymerization This procedure employs a technology called photo polymerization, in which radiation-curable resins or photopolymers are utilized to ultraviolet light to generate three-dimensional objects selectively. When these materials are exposed to air, they undergo a chemical reaction and solidify. Stereo lithography, Digital Light Processing, and Continuous Digital Light Processing are the three primary subcategories. Binder Jetting Binder jetting is a process that deposits a binding agent, typically in liquid form, selectively onto powdered material. The print head deposits alternating layers of bonding agent and construction material and a powder spreader to create a three-dimensional object. Material Extrusion S. Scott Crump invented and patented material extrusion in the 1980s using Fused Deposition Modeling (FDM). The continuous thermoplastic filament is fed through a heated nozzle and then deposited layer by layer onto the build platform to produce the object. Powder Bed Fusion Powder bed fusion procedures, particularly selective laser sintering, were the pioneers of industrial additive manufacturing. This approach melts the powdered material and fuses it using a laser or electron beam to form a tangible item. The primary kinds of powder bed fusion are direct metal laser sintering, selective laser sintering, multi-jet fusion, electron beam melting, selective laser melting, and selective heat sintering. Sheet Lamination Sheet lamination is a catch-all term encompassing ultrasonic additive manufacturing, selective deposition lamination, and laminated object manufacturing. All of these technologies stack and laminate sheets of material to form three-dimensional objects. After the object is constructed, the parts' undesirable areas are gradually removed layer by layer. Directed Energy Deposition Directed energy deposition technology employs thermal energy to melt and fuse the materials to form a three-dimensional object. These are pretty similar to welding processes, but are much more intricate. Which Additive Manufacturing Process is best? Why? Based on three fundamental factors, additive manufacturing techniques are categorized into seven types. First, the way material is solidified is determined first by the type of material employed, then by the deposition technique, and finally by how the material is solidified. The end-user often chooses an additive manufacturing technique that best suits his requirements, followed by the explicit material for the process and application, out of the seven basic additive manufacturing processes. Polymer materials are commonly used in AM techniques because they are adaptable to various procedures and can be modified to complicated geometries with high precision. Carbon-based compounds are used to strengthen polymers. Polymers, both solid and liquid, have been widely used due to the variety of shapes, formability, and end-use qualities available. Wherever the light-activated polymer contacts the liquid's surface, it instantly solidifies. Photo polymerization, powder bed fusion, material jetting, and material extrusion are the most common additive manufacturing procedures for polymers. The materials employed in these processes can be liquid, powder, or solid (formed materials such as polymer film or filament). How BASF is Using Additive Manufacturing BASF is a chemical company. BASF, one of the world's major chemical companies, manufactures and provides a range of 3D printing filaments, resins, and powders within its extensive material portfolio. The company, well-known in the 3D printing sector, has formed major material agreements with several 3D printer manufacturers, including HP, BigRep, Essentium, BCN3D, and others. BASF went even further in 2017 by establishing BASF 3D printing Solutions GmbH (B3DPS) as a wholly-owned subsidiary to expand the company's 3D printing business. In addition, BASF stated last year that B3DPS would change its name to Forward AM. BASF's role in the 3D printing business, however, is not limited to material development. BASF has made several investments in 3D printing companies over the years, including the acquisition of Sculpteo, one of the significant French 3D printing service bureaus, last year. BASF sees 3D printing as having a bright future. With the growing popularity of professional 3D printers, all of these systems will eventually require robust, high-quality polymer materials to perform at their best – and BASF has been paving the way to becoming one of the leading solution providers. Final Words All additive manufacturing procedures are unique and helpful in their way. Still, some have additional advantages over others, such as the material used, highresolution, precision, and the ability to build complicated parts. Because of these added benefits, photopolymerization, material jetting, powder bed fusion, and material extrusion are preferred over others. Therefore, choose the AM process that is best suited to your manufacturing business and will assist you in achieving the desired final product output. FAQs What are the benefits of additive manufacturing? AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability. What is the major challenge in additive manufacturing? Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. So, this can be considered a significant challenge in additive manufacturing. What are the steps of additive manufacturing? The additive manufacturing steps are divided into four steps as below, Step1 - Design a model with CAD software Step2 -Pre-processing Step3 -Printing Step4 - Post-processing { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What are the benefits of additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability." } },{ "@type": "Question", "name": "What is the major challenge in additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. 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Article | July 8, 2020

Nic Temple (pictured left) Vice President of US Sales, Global AGV shared the rationale for autonomous forklifts: any manufacturer operating two or more forklifts currently, must consider the merits of replacing one unit as a critical return-to-work strategy during the pandemic. Fewer than 2% of forklifts sold in North America are automated, yet there has never been a greater need for this technology. Many manufacturers are looking to automate material handling processes because it reduces the potential for COVID-19 exposure by reducing human contact. Essential manufacturers working throughout the pandemic have been forced to deal with social distancing and PPE (personal protection equipment) required for employee safety. The money that manufacturers must spend on masks, gloves, face shields, and Lexan plastic partitions is difficult to recoup for a small or midsized operation. Temple shared that automated material handling helps a company keep working through these challenges as the only viable return-to-work strategy. A single autonomous forklift can achieve 60% savings on day-to-day operations With a single autonomous forklift these smaller manufacturers can easily achieve a 60% savings on day-to-day operations shifting away from driver-operated forklifts. 60% Savings on Day-to-Day Operations

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Factors Explaining Why American Manufacturing Is Growing

Article | July 11, 2022

Even though Silicon Valley has built its reputation on innovation, it is believed that it has lost its edge. Business entrepreneurs were encouraged to focus on gleaming venture capitalists, to sell bigger dreams to the most popular technology. The future of the American manufacturing industry is predicted to have more growth than the past two decades, and here are the reasons why: Excluding the Middleman: From ancient times, manufacturers sold through retailers who acted as middlemen in the distribution process, but with the upgradation of the industry, manufacturers can now directly connect to the consumers and the government. Rising Demand for US Made Products: The US population leans more towards products that are made in America. Hence, the manufacturers make extra efforts to produce high quality premium products for their customers. Customer Loyalty and Support: Customers love to connect with the brand and understand the brand’s struggle to manufacture and create excellent products. Engaging customers in the journey will help manufacturers gain insights and feedback, and improvise accordingly. People today are more keen towards seeing improvements sooner, and it has become much easier to hear from customers, iterate, fail, pivot, and improve quickly. Conscientious Capitalism’s Rise: When you take into account the carbon cost of transportation imports, there is another clear advantage to the growth of domestic production. Important financial advisors are also raising this alarm. For instance, the polypropylene required for the majority of PPE is manufactured in the U.S., transported to China, used to make masks, and then returned. Additionally, since at least 18% of air pollution is caused by ocean freight, domestic product manufacturing may benefit both the environment and consumer demand. Energy Costs: The cost of energy consumption in the United States is declining, which is crucial when competing with foreign companies. For the first time in modern history, domestic production has a strategic advantage because electricity is the second-highest cost after labor. Automation: The strategic advantage of cheap labour possessed by international competitors is eliminated by the growth of automation. Over the next ten years, robotic automation is expected to challenge enterprises that have relied on cheap labour as a competitive advantage, paving the way for a revival of American manufacturing.

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Prolec GE

Prolec GE, headquartered in Monterrey, Mexico, is dedicated to designing, manufacturing, and selling products and solutions for the generation, transmission, and distribution of electrical energy.

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MaxLinear Launches Product Design Kit for Active Electrical Cables Using Keystone PAM4 DSP

MaxLinear | February 02, 2024

MaxLinear, Inc. a leading provider of high-speed interconnect ICs enabling data center, metro, and wireless transport networks, announced the availability of a comprehensive product design kit (PDK) to optimize performance and accelerate the time to market for high-speed Active Electrical Cables (AEC) using MaxLinear’s 5nm PAM4 DSP, Keystone. The PDK is a cost-cutting and time-saving tool for cable manufacturers who want to quickly integrate Keystone into their active electrical cables. MaxLinear’s Keystone PAM4 DSP offers a significant power advantage in AEC applications, which is increasingly becoming a critical factor for hyperscale data centers. The use of 5nm CMOS technology enables designers and manufacturers to build high-speed cables that meet the need for low power, highly integrated, high performance interconnect solutions that will drive the next generation of hyperscale cloud networks. Manufacturers taking advantage of MaxLinear’s PDK to optimize cable designs using Keystone PAM4 DSP will gain a distinct advantage over competitor solutions when trying to maximize reach and minimize power consumption. The PDK makes Keystone easy to integrate with strong applications support, multiple tools to optimize and monitor performance, and reference designs (SW and HW) to accelerate integration. Sophisticated software allows for quick design optimization for the lowest possible power consumption and maximizing cable reach. Cable designers can constantly monitor performance, route signals from any port to any port, and take advantage of hitless firmware upgrades. “MaxLinear is focused on providing not only industry-leading interconnect technologies but also a comprehensive suite of tools to support our manufacturing and design partners,” said Drew Guckenberger, Vice President of High Speed Interconnect at MaxLinear. “Our development kit for our Keystone products provides them with a path to take products to market more quickly and more cost-effectively.” Active electrical cables (AECs) are revolutionizing data center connections. Unlike passive cables, they actively boost signals, allowing for longer distances (up to 7 meters for 400G), higher bandwidth, and thinner, lighter cables. This makes them ideal for high-speed applications like top-of-rack connections (connecting switches to servers within the same rack); direct digital control (enabling flexible interconnectivity within racks and across rows); and breakout solutions (splitting high-speed connections into multiple lower-speed channels). The high-speed interconnect market – which includes active optical cables, active electrical cables, direct attach copper cables, and others – is expected to grow to $17.1B by 2028, up from $10.7B in 2021 according to a market forecast report from The Insight Partners. The Keystone Family The Keystone 5nm DSP family caters to 400G and 800G applications, featuring a groundbreaking 106.25Gbps host side electrical I/O, aligning with the line side interface rate. Available variants support single-mode optics (EML and SiPh), multimode optics and Active Electrical Cables (AECs), offering comprehensive solutions with companion TIAs. Host side interfaces cover ethernet rates of 25G, 50G, and 100G per lane over C2M, MR, and LR host channels. The line side interfaces, tailored for 100G/λ DR, FR, and LR applications, also support these rates. These devices boast extensive DSP functionality, encompassing line-side transmitter DPD, TX FIR, receiver FFE, and DFE. With exceptional performance and signal integrity, these DSPs occupy a compact footprint (12mm x 13mm), ideal for next-gen module form-factors like QSFP-DD800 and OSFP800. Additionally, they are available as Known Good Die (KGD) for denser applications, such as OSFP-XD. About MaxLinear, Inc. MaxLinear, Inc. is a leading provider of radio frequency (RF), analog, digital, and mixed-signal integrated circuits for access and connectivity, wired and wireless infrastructure, and industrial and multimarket applications. MaxLinear is headquartered in Carlsbad, California. MaxLinear, the MaxLinear logo, any other MaxLinear trademarks are all property of MaxLinear, Inc. or one of MaxLinear's subsidiaries in the U.S.A. and other countries. All rights reserved.

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Robotics and Automation

Kardex and Addverb start partnership in the area of intralogistics software

Kardex | January 25, 2024

Kardex has agreed a strategic partnership with Addverb in the area of intralogistics software. Addverb is a leading global robotics and warehouse automation company based in India. The cooperation combines Kardex's expertise in the area of compact storage systems with Addverb's outstanding warehouse management technology. Addverb's highly innovative warehouse management system is based on a modern microservices architecture and fully operable in the cloud. The partnership between Kardex and Addverb enables an integrated and efficient solution package with the latest technologies in the area of warehouse management and automation. The overall package of Addverb software and Kardex storage systems offers seamlessly integrated and optimized storage processes for companies of all sizes in all industries. Addverb's warehouse management solution is based on a microservices architecture that makes it seamlessly scalable and extremely flexible. In addition to which it features a user-friendly interface that eases the implementation and administration. With its algorithms optimizing the handling of resources and materials, the Addverb system ensures optimized workflows and greater productivity. The cloud-based architecture meanwhile guarantees global access and real-time data for optimal decision-making with the highest possible security standards. The partnership between Kardex and Addverb is an important step forward in the advancement and innovation of warehouse management technologies. Both companies are convinced that their joint effort will contribute to boosting the efficiency and agility of companies worldwide. "Thanks to the partnership with Addverb, we are able to offer our clients one of the most advanced warehouse management solutions for highly efficient storage. The combination of our technologies will set new standards in the integration of logistics systems" emphasizes Dr. Volker Jungbluth, Head of Corporate Technology at Kardex. The strategic partnership enables extensive synergies between the two companies. "Together with Kardex, we will be able to offer our clients first-class solutions that will revolutionize their warehousing processes and make them more competitive", says Pieter Feenstra, CEO Addverb EMEA.

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