The Role of Engineering in Solving Industrial Pain Points

The Role of Engineering in Solving Industrial Pain Points

Industrial operations often face unique challenges, from inefficiencies in outdated systems to the need for automation and precision. These pain points can hinder productivity, increase costs, and complicate workflows. Enter engineered solutions—a tailored approach that integrates automation, control, and precision to optimize processes. Brechbuhler Scales, a leader in providing engineered solutions, specializes in designing and implementing systems that solve real-world problems, delivering long-term value to industries like logistics, manufacturing, and bulk handling.

In this article, we’ll explore the critical role of engineering in solving industrial pain points, focusing on the importance of site evaluations, collaborative design, and iterative problem-solving.

What Are Engineered Solutions?

Engineered solutions are customized systems designed to address specific pain points beyond what standard equipment can achieve. At Brechbuhler Scales, the process involves more than integrating hardware—it’s about creating turnkey solutions that automate processes, enhance efficiency, and adapt to evolving operational needs.

This comprehensive approach includes:

• Discovery and Site Evaluation: Understanding the client’s challenges and requirements.
• Engineering and Design: Developing tailored systems that integrate hardware and software seamlessly.
• Installation and Maintenance: Ensuring systems are operational, efficient, and future-ready.

From truck scales to conveyor systems and process control automation, engineered solutions solve inefficiencies and help businesses thrive in competitive industries.

Why Site Visits Matter in Developing Engineered Solutions

A thorough on-site evaluation is often the first step in addressing industrial pain points. As Jim Foley, a Brechbuhler expert, explains, “Nine times out of 10, it’s going to require a site visit.” This hands-on approach allows engineers to observe systems in action, identify inefficiencies, and gather crucial feedback from operators and supervisors.

During these visits, engineers:

• Document current processes and equipment performance.
• Identify challenges such as bottlenecks, outdated components, or inefficiencies.
• Collaborate with operators who provide real-world insights into system functionality.

For example, a packaging line with a conveyor system needed load cells integrated for weight checks. Engineers discovered that the conveyor’s photo-eye sensors caused system shutdowns when packages were delayed. This insight, gained through on-site observation, enabled them to design a solution that synchronized the conveyor sections and resolved the issue.

Collaboration Drives the Design Process

Operators and supervisors play a vital role in shaping engineered solutions. Their feedback highlights not just inefficiencies but also practical details that engineers might overlook. “Operators often have insights that save a lot of time and heartache,” says Foley.

Brechbuhler’s approach emphasizes this collaboration:

• Operators provide detailed observations about system performance and quirks.
• Supervisors help identify broader inefficiencies and goals for improvement.
• Engineers use this input to craft solutions tailored to the client’s needs.

This collaborative approach ensures that the resulting system is practical, efficient, and designed to address real-world challenges.

Case Study: Engineering a Conveyor System Solution

A recent project illustrates Brechbuhler’s problem-solving expertise. A client’s packaging line required weight-based checks for boxes. Engineers integrated load cells into the conveyor system, which worked flawlessly during initial tests. However, once installed, the system frequently shut down due to an overlooked issue with the conveyor’s independent controllers.

By working closely with operators and observing the system in action, the team identified the problem: the conveyor sections needed a signal to keep running. After working through several scenarios with the customer’s maintenance team for three days, the team was able to develop a solution to resolve the issue, delivering a fully function, optimized system.

This case underscores the value of on-site evaluations and collaboration in developing robust engineered solutions.

Serving Diverse Industries with Tailored Solutions

Brechbuhler’s expertise spans industries where precision, automation, and process control are essential. Their engineered solutions address challenges in:

• Logistics: Streamlining material handling with truck scale systems and in-motion checkweighers.
• Bulk Handling: Optimizing cement, grain, and coal loadout processes.
• Manufacturing: Enhancing packaging lines with automated weight checks and process controls.

By tailoring solutions to each client’s unique requirements, Brechbuhler ensures systems not only meet current needs but are also adaptable for future challenges.

Conclusion: Engineering for Efficiency and Success

Solving industrial pain points requires more than off-the-shelf equipment. Brechbuhler Scales’ engineered solutions deliver customized, comprehensive systems that optimize processes, reduce costs, and enhance productivity. From on-site evaluations to collaborative design and ongoing support, Brechbuhler’s approach ensures that every solution is built to last.

If your operations are facing inefficiencies, outdated systems, or the need for automation, contact Brechbuhler Scales today. Let our engineering expertise help you achieve streamlined, efficient processes tailored to your unique needs.