Warehouse & Logistics Archives - Relay

Lineage Westfield

Jess Fischer — Thu, 08 Jan 2026 20:19:56 +0000

LINEAGE WESTFIELD

Lineage Westfield Improves ROI and Slashes Turn Times up to 80%

RELAY PRODUCTS USED

USE CASES

By addressing the communication challenges of its freezer warehouse, the team at Lineage’s Westfield facility is now handling more trucks than ever, reducing turn times, and boosting team morale.

Slowed Down by Communication Gaps in the Freezer

In the fast-paced, cold storage environment of Lineage’s Westfield, Massachusetts facility, clear communication is essential for maintaining peak efficiency and excellent worker safety. Previously, the team relied on traditional two-way radios that struggled to penetrate the freezer’s thick, insulated walls. General Manager Matthew Fortune explained his frustration, “The problem with those radios is they couldn’t penetrate the freezer wall. We only had about a 40% connectivity rate.”

This spotty connection meant that 60% of the time, messages didn’t go through, so team members had to physically go and pass along messages in person. Warehouse Supervisor Ivan Serrano shared what the experience felt like prior to Relay, “I would physically go into the freezer, go down the aisles and scream for the operator to make sure they were seeing me.” This wasted valuable time and created operational bottlenecks, especially when coordinating tasks across the vast warehouse. For a company that prides itself on innovation as a core value, Fortune knew that enhancing team connectivity was the key to better serving their customers and improving the site’s ROI.

“We have significantly reduced our turn times over the past three years and now average between 35 and 45 minutes. The Relay devices had a huge impact on that.”
– Matthew Fortune, General Manager, Lineage Westfield, Massachusetts Warehouse

Achieving 98.7% Connectivity with Real-Time Location

The introduction of Relay was a significant step forward for the Westfield facility. With 98.7% connectivity throughout the warehouse, the team could finally communicate instantly, whether they were in the freezer, on the dock, or in the office.

A key feature for Fortune’s team was the ability to see a live map of the facility showing the exact location of every team member with their Relay. “The Relay devices give us a real-time location of our operators, which we did not have before, and it helps us make smarter, faster decisions that translate to better service for our customers.” This new visibility allowed supervisors to direct freight and coordinate tasks with greater efficiency, eliminating guesswork and wasted movement.

Reducing Turn Times up to 80%

The operational improvements were significant. With streamlined communication and location tracking, the team saw a major impact on their benchmarks. Truck turn-around times were reduced from 3-4 hours to an average of just 35-45 minutes. The facility went from handling 35-40 trucks a day to efficiently managing over 50, with the capacity to handle up to 60 trucks on busy days.

This boost in efficiency had a direct impact on the facility’s bottom line. “The return on investment in this building has improved since we brought the Relay devices in,” Fortune stated. “We’ve been able to handle more trucks than we have in the past.”

Built for the Demands of the Warehouse

Beyond the operational improvements, the team was impressed by how well Relay devices held up in the harsh cold of their warehouse environment.

Durability: In a warehouse environment, devices must perform and survive regular handling, as well as accidental drops. They’ve been durable, they’ve been strong, and they’ve kept operating the entire time,” shared Fortune.
Battery Life: Even in the energy-draining cold of the freezer, the Relays last. “When you’re in the cold, the battery goes down a lot quicker,” explained Operations Manager Cristian Acevedo. “The Relays are in there for hours and they last in the cold.”
Safety & Morale: The benefits have also extended to the team’s well-being. “These Relay devices have also helped us operate safer,” said Fortune. “If we see something that’s unsafe, we can call it over the Relay device and we know it’s going to transmit.” This reliability and connectivity also led to a noticeable boost in spirits. “Everybody was so happy,” Acevedo noted. “It just brought up their morale.”

A Recommendation for Any Warehouse

For Lineage’s Westfield team, switching to Relay was more than just a communication upgrade; it was a fundamental improvement to their entire operation. By connecting their team, they unlocked new levels of efficiency, improved safety, and created a more positive work environment.

Fortune’s advice to other facility managers is clear: “To increase efficiencies and ROI, I would highly recommend that people look into this program and try it out in their warehouse.”

24/7 cold storage facility in Westfield, Massachusetts
Large freezer warehouse with 20 aisles, managing 50-60 trucks daily
Specializing in the preservation, protection, and distribution of food for global brands

INDUSTRY

MANUFACTURING

OBJECTIVE

Replace an unreliable radio system that was prone to dead spots, hindering team safety and creating costly operational delays. The objective was to find a modern communication solution that could penetrate freezer walls, provide real-time team visibility, and ultimately increase the number of trucks the facility could service daily.

RESULT

After replacing traditional radios with Relay, Lineage’s Westfield, MA facility’s connectivity rate jumped from 40% to 98.7% within the freezer walls. This upgrade helped slash truck turn times from hours to 45 minutes, increased daily truck capacity, and improved both safety and team member experience through reliable, real-time communication and location tracking.

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Building a Culture of Innovation on the Shop Floor

Meghan Keith — Wed, 20 Aug 2025 18:31:59 +0000

New product design, automation, and state-of-the-art technology are frequently linked to innovation in manufacturing. However, true innovation flourishes on the shop floor, where parts are manufactured, machinery is operated, and issues are resolved daily. It does not only exist in R&D labs or executive meetings.

Establishing an innovative culture on the shop floor is now a competitive requirement rather than a “nice to have.” Encouraging your frontline teams to innovate is one of the most effective ways to stay ahead in a time of rapid technological change, labor shortages, global pressures, and customer expectations for better, faster, and less expensive results.

From leadership techniques to employee empowerment, communication, and continuous improvement, this article examines what it takes to create a shop floor culture that values innovation.

Why Innovation Belongs on the Shop Floor

The shop floor is the heart of any manufacturing operation because it’s where the action happens. Teams manufacture products, handle materials, monitor machines, and create value on the shop floor, making it a hub of practical insights.

Frontline employees directly witness inefficiencies, equipment malfunctions, material waste, and safety hazards. They are the first to notice when a setup takes longer than necessary or when a process slows down. They are also in the best position to develop and implement practical solutions if they have the appropriate resources and support.

Fostering a culture of innovation on the shop floor can yield substantial benefits:

Higher factory productivity through process improvements
Reduced waste and downtime
Faster problem-solving and decision-making
Improved employee morale and retention
Greater adaptability to customer or market demands

Yet many companies overlook this opportunity by failing to recognize the value of bottom-up innovation.

What Does a Culture of Innovation Look Like?

Even though technology is helpful, an innovative shop floor isn’t necessarily populated by robots and digital dashboards. Instead, people and practices define it by encouraging creative thinking, learning, experimentation, and problem-solving.

Key characteristics include:

Psychological safety: Workers can speak up and suggest ideas without fear of criticism.
Ownership and accountability: Employees may identify and address issues, rather than just reporting them up the chain of command.
Continuous learning: Teams are encouraged to seek new skills, share knowledge, and learn from mistakes.
Structured idea channels: There are clear pathways for proposing, testing, and implementing improvements.
Recognition and feedback: Good ideas are acknowledged, celebrated, and rewarded.

Leadership: Setting the Tone from the Top

Leadership is the foundation of culture. Innovation won’t be prioritized on the floor if it isn’t at the top.

All levels of leaders, including supervisors, plant managers, and executives, are essential in establishing standards and providing behavioral examples. Among the top leadership techniques are:

Make innovation a part of the mission: Discuss it frequently. Tie it to company goals, such as quality, safety, and customer satisfaction.
Lead by example: Show openness to new ideas. Ask questions. Experiment with various approaches in your decision-making.
Invest in training: Provide resources for lean manufacturing, Six Sigma, creative problem-solving, and other frameworks that equip employees with the tools to innovate.
Flatten hierarchies: Encourage direct communication across all levels. Create opportunities for workers to interact with leadership in meaningful ways.

A shop floor will only innovate when it knows leadership is listening—and willing to act.

Empowering the Frontline Workforce

Empowerment is the engine of innovation. Employees who take pride in their workplace are more inclined to question the status quo, find proactive solutions to issues, and make suggestions for enhancements.

Here’s how to empower your teams:

1. Promote Ideas from the Bottom Up

Provide staff members with avenues to share their ideas, such as digital platforms, whiteboards, and physical suggestion boxes.
Assign kaizen or continuous improvement projects to teams.
Establish cross-functional improvement teams that include maintenance personnel, quality personnel, and machine operators.

2. Provide Resources and Time

Set aside time during the workday for experiments, brainstorming, or improvement projects.
Make simple tools, software, or prototyping materials available so that new concepts can be tested quickly.

3. Celebrate Wins and Learn from Failures

Recognize employee contributions publicly—through shoutouts, bonuses, or awards.
Normalize that not every idea will succeed, but every effort helps the team learn.

4. Offer Autonomy

Allow experienced workers more freedom to adjust setups or tweak processes within clear safety and quality parameters.
Train employees to self-inspect and self-manage wherever possible.

Autonomy signals trust—and trust fuels initiative.

Bridging the Gap Between Engineering and the Shop Floor

Innovation often fails when ideas are siloed between departments. Engineers may design solutions that don’t work well in practice, while operators may encounter daily pain points that are never addressed.

To bridge this gap:

Invite shop floor workers into design reviews or process planning meetings.
Use feedback loops—implement pilot changes and gather structured feedback before rolling out new procedures plant-wide.
Establish cross-functional teams that include production staff, engineers, quality personnel, and logistics personnel to co-create solutions.

The result is better collaboration, fewer surprises, and solutions that work in the real world.

The Role of Technology: Enabler, Not Driver

Although they are effective, digital tools like real-time dashboards, AI-powered monitoring systems, and Industrial IoT (IIoT) do not alone foster an innovative culture. Technology is not a driver; it is an enabler.

But when paired with an improvement-oriented and inquisitive culture, technology can:

Highlight bottlenecks, enabling more targeted improvements
Automate repetitive tasks, freeing workers to focus on higher-value activities
Enable better communication through mobile tools or digital work instructions
Provide instant access to training, standards, and troubleshooting guides

The key is to choose tools that serve the workforce—not replace it.

Relay was built with this philosophy in mind: to enable seamless, real-time communication that supports your workforce and helps unlock smarter, safer operations. Explore our solution at your own pace in our on-demand video demo center.

Training and Upskilling: Building the Innovation Muscle

Innovation requires knowledge. Workers must understand not just what they do, but why they do it—and how it fits into the larger operation. That’s where training and upskilling employees comes in.

A strong training program supports innovation in several ways:

Onboarding that emphasizes problem-solving as part of the role
Regular cross-training to increase flexibility and broader process awareness
Workshops or certifications in lean, Six Sigma, 5S, root cause analysis, etc.
Mentorship programs that pair seasoned operators with newer employees to transfer tribal knowledge

Skilled, confident workers are more willing to contribute new ideas—and more capable of making them happen.

Measuring Innovation on the Shop Floor

What gets measured gets improved. Tracking innovation doesn’t mean just counting patents or R&D spend. Instead, consider metrics like:

Number of employee improvement suggestions submitted and implemented
Percentage of frontline teams involved in improvement initiatives
Reduction in downtime, scrap, or rework tied to shop floor-driven improvements
Productivity gains from process changes initiated by workers
Employee satisfaction and retention rates

Even qualitative feedback—such as surveys or town hall comments—can offer insight into whether your culture is moving in the right direction.

Overcoming Common Barriers

Creating an innovative culture is not without its difficulties. Typical challenges consist of:

Fear of failure: If errors are penalized, employees might be reluctant to propose changes.
Lack of time: Strict deadlines and output targets may not allow much time for introspection or trial and error.
Opposition to change: Certain teams might be dubious, particularly if earlier attempts at improvement were disregarded or shelved.
Communication breakdowns: Without a defined procedure for assessing and implementing good ideas, they may never get spoken.
Language barriers: When teams speak different languages, valuable ideas can be lost in translation, and misunderstandings can hinder collaboration.

The solution is to address these issues directly. Build safety nets for experimentation. Make time for improvement in the schedule. Demonstrate follow-through on ideas. And keep lines of communication open at all times.

Final Thoughts: Start Small, Think Big

Building a culture of innovation on the shop floor doesn’t require a considerable budget or radical change. It begins with listening to your people, empowering them to think creatively, and fostering an environment where learning and improvement are integral to the job.

When workers feel heard, supported, and trusted, they stop just running the machines—and start improving the business.

Innovation isn’t a department. It’s a mindset. And it belongs everywhere—including your shop floor. For your next read, check out our guide to overcoming resistance to change when implementing new technology.

The post Building a Culture of Innovation on the Shop Floor appeared first on Relay.

Sauder’s Eggs

Jess Fischer — Wed, 13 Aug 2025 14:53:44 +0000

SAUDER’S EGGS

Sauder's Eggs Cracks Communication Barriers, Boosting Efficiency and Morale

RELAY PRODUCTS USED

TEAM COMMUNICATIONS

TEAMTRANSLATE™

USE CASES

Faced with a noisy production floor and a linguistically diverse workforce, the family-farm-focused egg packer turned to Relay to improve safety, streamline operations, and build a more inclusive and connected team culture.

PHOTOGRAPH © SAUDER’S EGGS

An Egg-Packing Powerhouse with Family Roots

Sauder’s Eggs isn’t your average egg company. What began as a humble family operation in the 1930s has become one of the nation’s leading egg companies. For decades, they have built their business by partnering with over 100 local, family-owned farms across Pennsylvania and Ohio to deliver some of the freshest eggs possible. At their packing facilities, like the one in Lititz, PA, a dedicated team works around loud, fast-moving machinery to grade, pack, and ship fresh eggs to customers across the country.

A Scramble to Be Heard

Inside Sauder’s busy packing facilities, however, past communication methods couldn’t keep pace with their commitment to quality. Plant Manager Cody Rhinier, knew the old system was flawed. They had previously used traditional walkie-talkies with long cords that would snag on equipment. This led to a less-than-ideal workaround. “Half the time people were just yelling across the production floor,” Cody shared.

The challenge was compounded by a significant language barrier. With a team that is roughly 50% non-English speaking—including speakers of Spanish, Vietnamese, and Arabic—clear, real-time communication was often difficult, relying on typing into translation apps or using an on-call phone service. This not only slowed down operations but also limited opportunities for talented employees who weren’t fluent in English.

A Fresh Way to Connect the Flock

Having heard about Relay at a previous company, Cody knew it could be the right solution for their diverse Lititz, PA facility. He introduced the devices to bridge the gaps in their operations and the impact was immediate, especially for overcoming language barriers. No longer limited by impersonal apps, team members could now speak in their native language and be understood instantly by others.

This unlocked new potential for the team. “It’s easier to move some of these non-English-speaking employees into some more key positions that do require radios and communication,” Cody explained. “And now, we have some very good employees who don’t speak any English, but they’re some of my key people on the floor that I need every day.”

The change was deeply felt by employees. Cody shared a story about introducing the Relay device to a key Vietnamese-speaking line lead: “I spoke into it and she heard it in English and she goes, ‘oh good.’ And then it started translating in Vietnamese and she just kind of looked at me and she was so happy. It was just a really really cool reaction to see and now we use them every day.”

The sentiment was echoed by Sophie Schmitt, Senior Director of Marketing at Sauder’s Eggs who had recently been discussing the capabilities of Relay with Sauder’s CEO. She shared his feedback that he wished he had Relay back when he was running the plant because it was often difficult to be understood, resulting in wasted time and miscommunications.

Clearer Communication Delivers Grade A Results

With Relay in hand, Sauder’s has transformed its day-to-day operations. The crystal-clear audio has eliminated the need to shout over machinery, creating a more organized and professional environment. “With the radio’s running off 4G, I can hear them whether I’m here or if I run to another facility for something,” Cody adds, highlighting the reliability of the network.

Operational Efficiency: In egg packing, precision is everything. Miscommunication can lead to over-packing one order while shorting another. With Relay, the team can coordinate seamlessly. “It’s just crucial to have good communication to make sure orders are getting completed as efficiently as possible,” said Cody.
Enhanced Safety: Should a team member need assistance, they can use their Relays to instantly alert Cody and a supervisor, far faster than if they had to walk to the intercom, page someone, and wait for a callback or to be met at a specific location. The intercom system didn’t allow the team to communicate additional details quickly and could be difficult to hear over the facility’s loud machinery.
Stronger Culture: For Cody, the biggest change has been in the team’s culture. He can now connect with every employee, regardless of the language they speak. “I’m a huge people person, and when I come in on a Monday, I like to ask people how their weekend was. Before, I could only ask whoever spoke English, but now that we have so many different languages, I can go around, use the radio and ask everybody,” he said. This ability to build personal connections, he believes, is critical for retention.

“Relay creates a more personable experience and you build a stronger relationship with your employees. I think this will help make them feel more comfortable here and want to stay rather than go to another company where they can’t talk to anybody.”

– Cody Rhinier, Plant Manager, Sauder’s Eggs

For Sauder’s Eggs, the decision was simple. The affordability and immense value made it an easy choice. As Cody put it, the cost was a “no brainer.” By investing in their people and their ability to connect, Sauder’s Eggs didn’t just find a better walkie-talkie; they found a tool that strengthens their entire operation from the ground up.

Founded in the 1930’s
One of the nation’s leading egg companies, with five grading and processing facilities across three states

INDUSTRY

MANUFACTURING

OBJECTIVE

Sauder’s Eggs sought a reliable communication solution to replace their outdated walkie-talkies, aiming to overcome language barriers, improve safety, streamline operations, and build a more connected team culture.

RESULT

After implementing Relay, Sauder’s Eggs achieved seamless communication across their linguistically diverse workforce, enhancing safety with instant alerts, and ultimately fostering a more efficient and inclusive operation with a stronger team culture.

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Dutch Valley Foods

Jess Fischer — Fri, 01 Aug 2025 19:14:18 +0000

DUTCH VALLEY FOODS

Dutch Valley Foods Boosts Safety and Unifies Operations with Reliable Communication

PHOTOGRAPH © DUTCH VALLEY FOODS

RELAY PRODUCTS USED

TEAM COMMUNICATIONS

WORKER SAFETY

USE CASES

With a sprawling facility, spotty communication wasn’t just frustrating for the bulk food distributor, it was a safety concern. Dutch Valley Foods replaced its unreliable walkie-talkies with Relay, finally connecting its entire team, strengthening safety protocols, and creating a more secure and efficient workplace.

PHOTOGRAPH © DUTCH VALLEY FOODS

Three Businesses, One Need for Flawless Communication

On paper, Dutch Valley Foods is a busy bulk food distributor in Myerstown, Pennsylvania. But it operates as three businesses in one: a distributor shipping pallets of dry goods to everyone from farm stands to multi-chain grocers, a dry food production facility packaging everything from soup starters to trail mix, and a logistics company with its own fleet of 75 trucks and 150 trailers delivering to 29 states up and down the East Coast. Juggling all of this requires flawless communication to keep things running smoothly and safely.

A ‘Radio Graveyard’, Poor Connectivity, and Growing Safety Concerns

As Dutch Valley Foods grew, it physically expanded, adding on to its warehouse facility almost ten times. The result? A massive, complex layout full of concrete walls and floor-to-ceiling racks that made reliable communication nearly impossible. Not only did the business face extensive dead spots and range issues with these added materials, their previous off-the-shelf walkie-talkies couldn’t withstand the industrial elements.

This left Corporate Director of Safety and Compliance, Tom Houtz, with a “radio graveyard” of broken devices. He shared, “I mean it’s a warehouse environment, so all of our floors are concrete, so you drop one of those radios and it’s instantly done. I can take you out and show you the radio graveyard and antennas are broken off and the screens are cracked and there’s corners chipped out of them, it’s awful.”

The fragile devices and unreliable connectivity created significant safety vulnerabilities. This communication gap was often illustrated when a manufacturing employee would attempt to call for assistance, but their radio call couldn’t get through. For critical situations, like a worker needing help, the official plan relied on whistles to call for aid. In a large, noisy warehouse, there was a serious concern that a whistle could go unheard. Tom realized the urgent need for a more dependable system to protect the team.

Finally, a Device That Actually Worked

Tom Houtz led the charge to find a new solution, believing that “clear, concise communication is what drives a business forward.” Given his past experiences, he was cautious about trying another radio system. “We were a little hesitant as to whether or not it would work because we’ve just been burned so many times on radios,” he says. After a Google search, he found Relay and decided to move forward.

Unlike their previous devices, Relay promised total coverage. It also included a dedicated panic button, providing a modern and direct way for employees to signal for help which was a significant improvement to their existing safety protocols. The risk paid off. “It has worked flawlessly,” Tom says.

“We have 100% coverage everywhere in our building. We’ve never had that before.”
– Tom Houtz, CSP, MSP, Corporate Director of Safety and Compliance at Dutch Valley Foods

When evaluating Relay, battery life and audio output were also important. In the past, the team needed amplifiers to properly hear their radios. Now, “they can hear the Relays better than they even could with the amplifier,” shared Tom, even over loud dust fans. The battery life has also been a stark contrast. The team has accidentally gone two or three days without charging a Relay, and found that the device just keeps working. Previously, their radios would start to fade around hour 8 of a 12-hour shift.

Amazing Results Lead to a Quick Expansion and New Standard of Operations

Dutch Valley started small, with just 10 Relay devices for the order picking team. The reaction was instant. “We were like, ‘This thing is amazing. This is working really well,’” says Tom. It didn’t take long for other teams to see the benefits, who were more than ready for a reliable solution. “They immediately said, ‘We’re ditching our old radios. Let’s do the Relay thing,’” Tom recalls. Word spread, and soon the maintenance and manufacturing departments wanted in, too. Today, Dutch Valley Foods uses over 30 Relays and counting.

This rapid expansion was fueled by improvements that have changed the game for the entire team. The panic button isn’t just a feature; it’s a source of confidence, with Tom noting that after seeing the system work, “everybody gets a big sense of security by seeing the response.” Tom has also leveraged Relay to broadcast alerts to the entire team, “We had one drill here where I used the summon feature and called every user back to a main channel and was able to communicate to every single device out there. It was perfect.”

The devices themselves are tough, and with the geofencing feature, not a single one has been lost. Ultimately, this new internal efficiency translates to a better customer experience. With clear communication, the whole operation runs smoother. When a customer arrives, the team coordinates instantly.

“What our customers see is that we’re on top of our game. They see that we’re a well-communicating organization.”

– Tom Houtz, CSP, MSP, Corporate Director of Safety and Compliance at Dutch Valley Foods

Bulk food supplier headquartered in Myerstown, PA and founded in 1978
300,000+ sq ft of warehousing space featuring 5,000+ items

INDUSTRY

MANUFACTURING

OBJECTIVE

Dutch Valley Foods sought a reliable communication solution to replace their failing walkie-talkies, aiming to enhance safety, unify operations across their businesses, and improve overall efficiency.

RESULT

After implementing Relay, Dutch Valley Foods achieved full communication coverage throughout their facility, significantly enhancing safety with features like a dedicated panic button, and ultimately creating a more efficient and well-coordinated operation for their customers.

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The Impact of Artificial Intelligence on Modern Manufacturing

Meghan Keith — Thu, 31 Jul 2025 19:00:10 +0000

Artificial intelligence (AI) has evolved from being a distant concept to becoming a revolutionary force that can transform manufacturing operations. The manufacturing industry has experienced rapid change because AI-powered technologies now provide better productivity, waste reduction, quality, and flexibility.

This article examines how AI is transforming contemporary manufacturing through the optimization of supply chains, robotics, quality control, and predictive maintenance. It also explores the benefits, challenges, and potential future developments of manufacturing operations, which intelligent automation systems significantly impact.

From Automation to Autonomy: A New Era Begins

Traditional manufacturing has long relied on automation to streamline repetitive tasks. Conveyor belts, CNC machines, and industrial robots have improved productivity over the decades. But AI takes things a step further. Unlike conventional automation, which follows rigid, preprogrammed rules, AI systems can learn from data, adapt to changing conditions, and make decisions with minimal human input.

This shift from rule-based automation to data-driven autonomy is at the heart of what’s often referred to as Industry 4.0—the fourth industrial revolution. In this environment, machines not only work but also think, learn, and improve over time.

Key Applications of AI in Manufacturing

Integrating artificial intelligence into manufacturing operations offers a wide range of benefits that enhance efficiency, improve product quality, and drive long-term cost savings across the production lifecycle.

1. Predictive Maintenance

Thanks to AI, predictive maintenance helps manufacturers detect impending equipment failures. They do this by recognizing patterns in sensor data, including increased vibration, temperature changes, and acoustic signals. This feature lets manufacturers fix issues before they cause expensive repairs or unplanned production bottlenecks.

Predictive maintenance outperforms traditional preventive maintenance because it cuts down on unneeded servicing and decreases equipment breakdown risks. It can yield cost savings of between 8% and 12% compared to preventive maintenance and up to 40% compared to reactive maintenance.

2. AI-Powered Quality Control

Quality control benefits from AI-enabled computer vision systems that detect product defects with higher precision and speed than human vision. Real-time assessment of high-resolution camera images through machine learning algorithms enables the detection of small specification deviations in parts and assemblies.

The high precision of this system minimizes waste and rework, particularly in industries with tight tolerances, such as electronics, automotive, and aerospace. Machine learning models develop their capabilities through continuous improvement, leading to smarter quality assurance systems over time.

3. Smart Robotics and Cobots

The implementation of AI technology resulted in the creation of smart robots and collaborative robots (cobots) that now serve as standard equipment on factory floors. The main difference between traditional robots and cobots lies in their ability to work alongside humans in the same area while learning new tasks through minimal programming.

The robots employ AI processing of visual and auditory data as they navigate changing environments to perform complex or delicate operations. The technology enables manufacturers to adopt new production techniques for customized and small-batch manufacturing, which previously required extensive human labor.

4. Process Optimization

AI algorithms optimize manufacturing processes in real time. The systems track production data from machines and workstations to recommend modifications, which decrease energy usage, boost production rates, and optimize material usage. AI systems modify CNC machine tool parameters, including speed, feed rate, and depth of cut, to preserve part quality during changes in material properties and ambient conditions.

5. Management of the Supply Chain

AI’s effects on supply chain logistics benefit the manufacturing ecosystem. Manufacturers can enhance their inventory management and shipping routes by utilizing intelligent forecasting tools to predict demand more accurately.

AI platforms use data analysis to spot supply chain interruptions like supplier delays and geopolitical threats and then offer suggestions to reduce risks. In the current unstable global environment, the ability to quickly adapt becomes even more crucial.

Benefits of AI Integration in Manufacturing

As AI technologies become more deeply embedded in factory operations, manufacturers are beginning to realize a host of tangible benefits that go beyond automation—transforming how products are made, monitored, and delivered.

1. An Increase in Efficiency and Productivity

AI can automate complex decision-making processes that result in better resource allocation and faster production cycles. By scheduling tasks on a production line or balancing energy loads, artificial intelligence helps manufacturers accomplish more work in less time.

2. Better Product Quality

AI helps produce more reliable and defect-free products by improving quality control and lowering human error. Manufacturers can enhance adherence to industry standards and maintain tighter tolerances.

3. Lower Prices

AI offers major cost advantages, ranging from reduced maintenance costs to energy savings and improved workflows. These efficiencies add up over time, providing businesses a competitive advantage.

4. Greater Personalization and Adaptability

AI makes it easier for manufacturers to quickly switch between different product types or processes. Low-volume, high-mix production models that adjust to changing consumer demands are thus encouraged.

5. Using Data to Make Decisions

With AI, manufacturers can glean valuable insights from their data. Dashboards and analytics tools convert raw data into actionable intelligence, enabling better strategic decisions across operations.

Challenges and Considerations

AI integration in manufacturing faces several obstacles despite its potential advantages.

1. High Initial Investment

Deploying AI systems, which include complex robotics and specialized machine learning models, is very expensive. Small manufacturing firms struggle to justify their initial expenditures because they lack a clear return on investment.

2. Data Quality and Integrity

AI thrives on data. Many factories experience data fragmentation and poor data quality as a result of their isolated information. Integrating contemporary sensors with legacy equipment while maintaining steady data flow is a major technical challenge.

3. Workforce Disruption

Automation raises concerns about job displacement. The implementation of AI technology creates new positions in programming, data analysis, and robotics maintenance, but it also leads to the elimination of specific traditional roles. The workforce requires proper reskilling to facilitate a seamless transition between old and new systems.

4. Cybersecurity Risks

Increased connectivity in smart factories introduces more attack surfaces. Protecting intellectual property and operational data from cyber threats becomes critical as AI adoption grows.

The Future of AI in Manufacturing

Thanks to technologies like digital twins, which are virtual representations of physical systems, manufacturers will be able to model and optimize processes before implementing the changes in the real world.

Meanwhile, advances in generative AI could enable machines to design parts, fixtures, or even entire production lines autonomously based on design constraints and performance goals.

The increasing demand for sustainable manufacturing will make AI essential for monitoring emissions, optimizing energy consumption, and implementing circular economy principles.

Conclusion

Artificial intelligence transforms manufacturing operations. It enables manufacturers to achieve flexibility and effectiveness, along with market competitiveness, through its various applications that include supply chain resilience, robotic collaboration, and predictive maintenance. The implementation of this change presents several challenges, including workforce disruption, data integration, and investment costs.

Businesses must implement AI strategically by investing in people, procedures, and long-term change management in addition to technology. The industry’s future development will empower manufacturers rather than replace them, and those who implement intelligent automation today will become leaders in the smart factories of tomorrow.

The post The Impact of Artificial Intelligence on Modern Manufacturing appeared first on Relay.

Magic Laundry Services

Jess Fischer — Wed, 02 Jul 2025 17:00:36 +0000

MAGIC LAUNDRY SERVICES

Magic Laundry Services Unifies Multi-Facility Operations and Boosts Efficiency with Relay

RELAY PRODUCTS USED

TEAM COMMUNICATIONS

USE CASES

For Magic Laundry Services, coordinating operations across three bustling, industrial-sized facilities is vital to serving its high-profile hospitality clients. The business’ previous walkie-talkies were bulky to carry, prone to breakage, and suffered from limited range, leading to wasted time and operational delays. Switching to Relay has provided seamless inter-building communication, more device accountability, and powerful management features, significantly streamlining workflows and reducing downtime.

Orchestrating Laundry Services for Hospitality Giants

Magic Laundry Services operates a large-scale industrial laundry service in Montabello, California, processing high-quality linens for an impressive roster of clients including local high-end hotels, resorts, and casinos, across three adjacent buildings. Joe Gayton, Assistant VP at Magic Laundry Services, described their environment on a typical day, “We have automated equipment. We have people digging inside of laundry carts, putting linen in, taking it out, sorting linen, walking here, walking there. It’s a lot of moving parts, machines, equipment, bells, whistles, you name it. There’s a whole lot going on.”

In this fast-paced setting, with departments from transportation and engineering to production all requiring constant coordination, clear and reliable communication is not just a convenience, but an operational necessity.

The Challenge: Breakdowns, Blind Spots, and Wasted Steps

Before adopting Relay, Magic Laundry Services relied on traditional walkie-talkies, which they found cumbersome and prone to breakage. Gayton recounted, “We used to have these old black walkie-talkies, kind of big ones, that you would clip on your belt. Then you’d climb on a machine and it would get caught, slip, fall, and break.” Not only were these awkward to carry, but each broken unit meant a significant expense. Furthermore, when these walkie-talkies broke, repairs could take a long time. Gayton noted, “We would send them to go get repaired and it would be out a month or six weeks or longer.”

The range of the walkie-talkies had often fallen short, impacting communications between the three buildings. When this happened, significant time was lost getting messages to the right person, as Gayton and his team would spend significant time walking within or between the buildings. Channel management also proved problematic, “Each building would be on one channel, but then everybody would forget to change channels to communicate.” Due to the business’ fast-paced operations, losing time and missing messages was far from ideal.

Finding the Right Solution in Relay: Already Trusted By Current Clients

About three years ago, with their existing walkie-talkie stock dwindling, Gayton began searching for a better alternative and discovered Relay on LinkedIn. His research revealed that many hotels, including Magic Laundry Services’s own clientele, were using the system for communications. After getting positive feedback from one of their clients, he approached Relay.

The key selling points for Magic Laundry Services included Relay’s competitive pricing and significant added features. “You’re going to get so much more for less money,” Gayton explained, mentioning GPS tracking, geofencing, and language translation. “It was a pretty easy sell,” Gayton recalled. “But cost isn’t always the main thing. It’s also performance, availability, effectiveness, those kinds of things.”

Additionally, he also noted the convenience for managers like himself, “I’m the assistant VP here now, so I’m on call 24/7 anyways and this is just another tool that helps me to be able to do that,” adding that with Relay on his phone, he can be two miles away and still keep in touch with his team.

Transformative Results: Streamlined Operations, Enhanced Oversight, and Proven ROI

The switch to Relay immediately brought some substantial improvements, with Magic Laundry Services seeing an increase in the efficiency of communication between buildings due to Relay’s more reliable connectivity. Gayton shared, “Now with the Relays, we’re able to communicate a lot more effectively and in a timely manner.”

On top of that, the business is seeing cost savings from not having to frequently replace broken devices like they used to, “There hasn’t been any replacements or repairs or anything like that since the new ones we got. So, I think in that sense, we are saving money.” Not only are Relay’s devices more durable, but their smaller, more manageable size has been an improvement for the staff carrying them to communicate across the facilities.

Gayton has also enjoyed the extra operational insights he’s gained with Relay. “I’m able to monitor all of the voice traffic and let’s say two people are having a problem trying to fix a machine or something, I can chime in or I can go out there and help.” Relay’s geofencing and GPS tracking has been invaluable for locating misplaced devices and preventing them from getting lost off-property in the first place. Looking forward, Magic Laundry Services also plans to leverage Relay for their facility, about 60 miles away.

“I would say the biggest plus for us is that we don’t have to go walk to find anybody, being that it’s such a big facility and three separate buildings. Now we’re able to communicate with another employee in another building. If I need something or something’s coming, I can let them know without me having to stop what I’m doing to go find them, and then come all the way back. So, we’ve been able to save a lot of wasted time.”
– Joe Gayton Assistant VP at Magic Laundry Services

The largest hospitality linen provider in Southern California
Operated across three separate plants on a single property
Located Montabello, California

INDUSTRY

MANUFACTURING

OBJECTIVE

Magic Laundry Services aimed to boost efficiency and unify operations across their three facilities by replacing their unreliable, bulky, and limited-range walkie-talkies.

RESULT

Switching to Relay drastically reducing the time previously wasted on manual communication and device issues, enhanced operational efficiency. Magic Laundry Services has also experienced substantial cost savings by eliminating the need for frequent repairs and replacements of their old, easily broken walkie-talkies.

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Crisis Management Strategies to Protect Your Team, Operations, and Reputation

Meghan Keith — Mon, 30 Jun 2025 18:08:47 +0000

You’ve got the routine of running a factory or warehouse during normal operations down to the letter. However, what happens when that routine is suddenly disrupted? Whether it’s a hurricane knocking out power or a cyberattack disrupting your internal systems, even a brief disruption can bring operations to a standstill. That’s why crisis management strategies should be in place well before any emergency occurs.

This guide covers the steps that matter when routine breaks down—from team coordination to recovery and communication.

Reliable Crisis Management Strategies

Before we go any further, let’s discuss the importance of making sure your entire team is on the same page. If even one person doesn’t know the role they’ll play, then things could go haywire during a crisis situation. Having regular redundant training and trial runs might make your team miss out on a few minutes of work, but you’ll be extremely glad you prepared if a crisis strikes.

With that in mind, here are several proven crisis management strategies to guide your team, before, during, and after an emergency.

Develop Contingency Plans

Aside from training, you’ll also need to come up with contingency plans. For example, if your internet goes down due to a cyberattack, what will your team do? If you don’t know, that could present a huge problem down the line. By planning in advance, though, you could ensure that locked in hot spots are available to instantly take over, if needed. Properly implementing strategic crisis management in advance means not having to call all your company’s shareholders due to an extensive internet outage.

Conduct Risk Assessments

Conducting risk assessments is a good way to uncover weaknesses that could lead to bigger problems. Let’s go back to the cyberattack example. During a routine risk assessment, you might find that employees aren’t trained to recognize social engineering tactics like phishing emails. That’s a huge gap which could give bad players access to your internal systems. In this event, a basic training program can serve as a simple but powerful element of your crisis management strategy, helping to prevent a security breach before it ever happens.

Identify Early Warning Signs

It’s easy to become complacent when you see the same things at work on a daily basis. Unfortunately, this means your crisis management strategies could begin to slip. Instead, get into the habit of looking around your factory for any potential vulnerabilities. By collecting and analyzing data regarding these vulnerabilities, you’ll be in a much better position to ward off having to utilize your crisis management techniques.

Contain the Damage

Once you become aware that your crisis management strategies are needed, it’s critical to protect your company’s people and assets. Let’s say that a tornado is headed to your facility and expected to hit within the next 10 minutes. By preparing in advance for this with trial runs, your team should be in a good position to quickly reach either an interior room or a hallway on the first floor. Take care not to incite the more excitable members of your team. Instead, use a calm and rational yet firm tone when you give the evacuation order.

Appoint a Crisis Management Team

Getting your team into a safe position is only one step of the process. Having a crisis management team in place will give your employees someone to connect with if they become alarmed, start to forget their crisis preparation, etc. Ensure that everyone has a smart radio such as RelayX to stay in touch. Not only will these smart radios keep working when phone lines have gone dead, but they also feature safety alerts and language translation capabilities. In other words, they’ll make the evacuation process much smoother.

Communicate Clearly with the Outside World

Regardless of the type of emergency, you’ll most likely need to share the news with people who are outside of your facility. A prime example comes in the aftermath of a tornado or hurricane that blew part of the roof off your factory. You’ll want to get ahead of the situation by announcing the problem yourself. That way, you can also take control of the narrative to protect your company’s reputation. Always remember, someone is going to break the news. Therefore, it’s almost always better if your business, following factual review and legal approval, is the one to do so.

Initiate the Recovery Process

Once the immediate crisis has passed, the recovery phase begins. During this time, focus on rebuilding operations while reinforcing public trust. Let’s say a hurricane causes major damage to your area and temporarily shuts down your facility.

Even if the situation wasn’t preventable, how you respond can shape long-term perception. Helping affected employees with emergency support, offering paid off time during recovery, or donating supplies locally not only shows leadership, it also signals your commitment to your team and community. These actions, rooted in compassion, also serve to protect and strengthen your company’s reputation.

Perform a Post-Crisis Assessment

Anytime an emergency arises, be sure to conduct a post-crisis assessment once the danger passes. Imagine that there are four different entry points in your warehouse, and three of them are supposed to be locked from the outside at all times. Somehow, though, an unauthorized individual gained access through one of these doors.

The first thing you’ll need to do during your post-crisis assessment is figure out how they did it. Is there a problem with the lock? Did someone leave the door propped open? Was your door lock easy to pick? Whatever you discover needs to be included in your post-crisis assessment. Of course, you’ll also want to adapt your techniques so that it can never happen again.

Adapt Based on Lessons Learned

Your crisis management strategies are likely to evolve based on what you learn from an actual emergency. Therefore, you should immediately update your strategies to include new techniques for handling a crisis. If one part of your plan doesn’t work as well as expected, as in the above example, you should reevaluate and come up with a better plan.

The reality is that as much as we want to always make the right decisions, we’re also human and will make mistakes from time to time. Get ahead of your mistakes in the press and be prepared to show how you’ve adjusted your crisis management strategies going forward.

Five Considerations for Crisis Management Strategies

Before you release a crisis management plan, it’s vital to take the time to carefully consider how it will affect your company post-crisis. Because at the end of the day, reputation management is one of the most important things your business can undertake.

As you build or refine your crisis management plan, keep these five considerations in mind to guide smart decision-making during emergencies and throughout the entire recovery process.

1. Leadership

Choosing your crisis management team requires you to pick out strong leaders that have the ability to calmly provide guidance when things go haywire. Select leaders that others trust and listen to closely.

2. Reputation

Your chosen crisis management team must also fully understand the importance of protecting your company’s reputation. Ensure that they’re ready to quickly issue a transparent statement to the press.

3. Ethical Standards

Lapses in proper and ethical decision-making could become a news story in the aftermath of a crisis. Instead, think through your crisis management plan to ensure it has been built ethically, and with as much compassion as possible.

4. Flexibility

Sometimes, no matter how much work you’ve put into your crisis management strategies, it becomes abundantly clear during an emergency that your plan isn’t working. While some people will insist on following the plan no matter what, effective leaders know when to pivot. For instance, what if part of your plan includes meeting in an area that is currently flooded? The ability to quickly assess the situation and adjust your response is a critical part of leading through a crisis.

5. Communication

Maintaining clear, consistent communication throughout the crisis – and afterwards with your employees – provides a proven way to get through a bad situation as a team. For staying in touch with your employees, we suggest utilizing smart radios. Unlike two-way radios that have range limitations, smart radios like Relay makes it easy to talk via multiple nationwide 4G LTE networks and WiFi. Therefore, they’re a much more reliable way to communicate, which is exactly what you need in a crisis situation.

Crisis Management Strategies That Work

The previously listed techniques for crisis management are the best way to come out the other side with your reputation, operations, and team intact. If you don’t currently have a crisis plan, consider working on one today. After all, you don’t want to get caught in a serious emergency without having previously thought it through. Are you looking for a way to improve your team’s communication skills? Whether you turn to us for better crisis management or to improve your team’s communication abilities altogether, Relay can make life significantly easier. Contact us today to receive a free demo!

The post Crisis Management Strategies to Protect Your Team, Operations, and Reputation appeared first on Relay.

8 Proven Ways to Improve Factory Productivity

Jess Fischer — Thu, 19 Jun 2025 20:49:39 +0000

Wondering how to improve factory productivity? Improving your business’ productivity in the factory takes a comprehensive approach, including leveraging technology and boosting the work environment. While individual productivity is also important, factory productivity refers to a ratio of output to input. In short, materials, labor, and capital are the input, and the finished product is the output.

Of course, if your individual workers aren’t happy, they probably won’t work to their full potential. In fact, Gallup research has indicated that unhappy workers cost U.S. businesses a whopping $1.9 trillion annually. Therefore, it’s vital to balance your factory’s needs with the needs of your employees. Done correctly, a successful combination of these priorities can boost overall factory productivity.

How to Improve Factory Productivity in 8 Steps

Boosting productivity and efficiency is a proven way to improve profits and make your employees feel more satisfied at work. Utilize the following eight tips to help give your company a much-needed boost.

1. Lean into Lean Manufacturing

At first glance, the idea of ‘lean manufacturing’ doesn’t sound employee-based. However, what it actually means is to reduce waste and optimize workflows. Furthermore, lean manufacturing includes the elimination of any non-value-added activities.

One proven way to identify and eliminate wastefulness is through a Kaizen event. Invite everyone from C-suite executives to brand new employees. During this 3-5 day event, your company can brainstorm solutions to improve wasteful practices such as:

Non-utilized talent – Repositioning employees whose skills go unused due to poor task allocation or management decisions.
Defects – Flawed products that require rework (and related overtime), create waste materials, or lead to dissatisfied customers.
Extra processing – Unnecessary steps in production that do not add any value to the final product.
Overproduction – Making more of a product than demand requires, leading to storage and wasted resources.
Motion (Muda) – Excessive movement by employees or machines that adds no value. In Lean Manufacturing, this type of motion is classified as muda, or waste.
Transportation – Inefficient or unnecessary transport routes or systems that increase time and cost.
Excess inventory – Storing more finished goods (FIGO) materials, or work in process (WIP) than necessary, which increases holding and inventory control costs.
Waiting – Idle time when workers or machines are delayed by earlier steps in the process.

Pro tip: Invite personnel who are directly involved in or impacted by the factory process targeted for improvement. That way, the team contributing to the Kaizen event has a real “stake” in the outcome, making them more engaged and motivated to drive meaningful change. After all, that’s where the term “stakeholders” came from!

2. Optimize Your Factory’s Layout

Imagine your factory is split into four zones: A, B, C, and D. Optimizing your layout means eliminating things that stand in your workers’ way.

For instance, let’s say that an employee works in zone A, but they have to walk over to zone D a few times a day to get their work done. If you were to optimize your layout, you might choose to have your zone A worker switch to zone D. That way, they don’t have to walk far to finish their job, which is an example of better material flow. By eliminating these extra steps, you can improve factory productivity.

Other things you should consider when optimizing your layout include employee morale, safety, flexibility, technology, and future growth. People typically don’t want their workstation’s location to be changed several times in a short period, so do a thorough workflow analysis to ensure you get it right the first time.

3. Leverage Automation to Save Time

Automation is a term that can scare workers, but it doesn’t need to be. The entire purpose of automation is to have machines or robots focusing on repetitive tasks that workers don’t enjoy doing. By freeing your employees from small, repetitive tasks, they can take on higher-value work. It works as a win-win for you and your employees! That’s why if you’ve been wondering how to improve factory productivity, leveraging automation is a great way to save time.

4. Enhance Communication Tools

White-collar workers who typically spend their time on a computer have a wide range of options available to communicate with each other. Tools like email, video conferencing, webinar tools, online whiteboard collaboration, etc. are all useful, as are social media and Slack. But what about your employees who work on the line? They often utilize other forms of communication tools.

Fortunately, you can use smart radios to enable workers to stay in contact with each other. With capabilities unique from traditional walkie-talkies, smart radios such as Relay have a much wider range and offer vital tools like TeamTranslate that instantly translate more than 30 languages. By putting this one tool in place, you can reduce language-related workplace accidents by 25%. Even better, Relay provides panic alerts and GPS location tracking, so if something is amiss, or a lone worker is in trouble, your team can respond immediately.

Is your team not using radios effectively and you’ve been looking for a better way to streamline communications? Whether you’re looking for a tool with better reliability, easier adoption, or added safety enhancements, book a 1:1 demo with a Relay product expert to learn why we might be a better fit!

5. Provide Proper Training to Boost Employee Engagement

If you want to improve workplace productivity, you should also enhance your training sessions. According to Industry Week, a third of all workers in the U.S. don’t receive any formal training. Instead, they’re simply thrown into the mix and have to figure everything out on the job. Furthermore, only about 24% of frontline workers feel like they’ve been adequately trained for their job.

If you take the time to provide proper training, your employees can reward you with 20% more productivity. It goes much further than that, though, as they’ll also be happier, more confident workers who are less likely to make costly mistakes. Currently, an estimated 61% of employees deal with symptoms of anxiety, anger, depression, fatigue, aches, etc. related to their workplace. Given that employee disengagement costs U.S. companies around $550 billion per year, focusing on providing effective team member training and boosting employee satisfaction can result in a substantial, positive corporate impact. Overall, the benefits of proper training include:

Better decision-making
Reduced absenteeism
Enhanced innovation
Lower turnover rate
Boosted productivity
A more positive work environment
Stronger talent recruitment
Improved customer service

Also, don’t forget about the importance of upskilling your employees. Not only do they need proper training, but they should also be given the opportunity to learn about data analysis, digital tools, and advanced manufacturing systems. Otherwise, the demand for their skills could diminish in the near future.

6. Use Preventative Maintenance Techniques

Every workplace wants to improve productivity and reduce downtime. However, this often gets undercut by attempts to cut costs, especially when it comes to equipment upkeep. Take something as essential as a conveyor belt.

When it’s not working, most factory operations grind to a halt. Yet, simple maintenance tasks like keeping it aligned or lubricated are often delayed or skipped entirely.

That short-term thinking can become very expensive. One industry group estimated that a broken conveyor belt can cost as much as $260,000 per hour, while another report places that cost closer than $22,000 per minute. And that’s just the immediate financial impact. There are also harder-to-measure effects like damaging customer trust, last minute labor costs, and the ripple effect of missing delivery deadlines.

Brightly, a Siemens company, reports that preventative maintenance programs can cut costs by up to 12% to 18% and generate up to a 400% return on investment. In other words, setting aside time and resources before problems happen does not waste money, it saves it.

And yet, 60% of companies still rely on run-to-failure strategies. Choosing to save a little now by skipping maintenance can end up exploding long-term costs. It’s a risky approach that sometimes backfires when unplanned downtime and emergency repairs through operations off course.

Make Maintenance Tasks Easy to Follow and Track

A good preventive strategy starts with consistency. Create a checklist that includes simple daily or weekly tasks, such as:

Visual inspections to spot where, misalignment, or damage
Cleaning to remove debris and reduce buildup around the system
Lubricating moving parts like bearings and drive components.
Testing safety systems such as emergency stops and machine guards.

Routine checklists help ensure no tasks slips through the cracks. Maintaining detailed maintenance records also helps identify recurring issues, track performance, and refine your strategy as patterns emerge. This type of documentation can make the difference between catching a small problem early on or facing a costly failure later.

7. Place an Emphasis on Factory Ergonomics

You probably already know that your white-collar workers prefer ergonomic workstations. But have you ever contemplated how to offer your frontline workers an ergonomic experience? It comes down to workstation design, tool selection, and material handling, and it can make a big difference to your factory’s productivity.

First up is workstation design. Each station on your factory floor should allow size adjustments because this will help people of a variety of body types do their job without added headaches. Choosing tools that promote neutral postures, while also being lightweight and easy to use, may help reduce workplace injuries. Finally, putting systems in place to help your employees push, pull, and lift heavy objects can improve workplace safety.

Again, this is something that simply makes good sense, yet many factory owners choose to ignore it. Do so at your own risk, though, as factory workers without good ergonomics are much more likely to face:

Musculoskeletal disorders
Reduced efficiency
Reduced productivity
Increased safety risk
Decreased job satisfaction

8. Incorporate Flexible Scheduling

If you really want your factory’s productivity to increase, you might want to consider incorporating flexible scheduling. To explain why, let’s use a single mother as an example.

You’ve got a great worker, but her productivity goes down at times and she’s always keeping an eye on the clock in the afternoon. You eventually discover that her child’s school day ends an hour before her workday, which gives her increased anxiety and reduces productivity during her last scheduled working hour.

By implementing flexible scheduling, such as letting your employee work from 8 a.m. – 2 p.m. and coming back from 4 p.m. – 6 p.m., you can help her balance external and workplace responsibilities. As a result, your employee’s productivity will remain consistent and she’ll be much more relaxed. Again, this is a win-win for both of you.

Even allowing occasional flexibility can keep your employees happier. After all, we’ve all had something important come up that we haven’t been able to attend due to our work schedules. Allowing people to adjust their schedule as needed will go a long way toward ensuring the proper work-life balance. Plus, it’ll be greatly appreciated by your employees, and happy workers are better workers.

Boost Productivity and Worker Happiness

As you’ve learned, there is a fine line between boosting factory productivity and keeping your workers happy enough to keep it up. Offering things such as preventative maintenance, factory ergonomics, and flexible scheduling will go a long way, though. Also, don’t forget about the importance of giving them enhanced communication tools so that help is only a button press away.

Want to learn more factory efficiency best practices like how to improve factory productivity? Sign up for our monthly resource newsletter!

The post 8 Proven Ways to Improve Factory Productivity appeared first on Relay.

Supply Chain Resilience: How Can Businesses Achieve It?

Jess Fischer — Fri, 13 Jun 2025 19:36:31 +0000

Although many descriptors have been applied to the supply chain recently, “resilience” is the one that businesses are focusing on the most. It refers to the ability of a supply chain network to anticipate, prepare for, adapt to, and recover rapidly from disruptions. Natural disasters, pandemics, geopolitical events, economic shifts, or unexpected market changes can cause those disruptions.

However, rather than simply managing risk, supply chain resilience emphasizes proactive and reactive strategies to ensure the continuity of operations and minimize the impact of upheaval on revenues, costs, and customer satisfaction.

Here are 10 suggestions to help you accomplish this:

1. Diversify Suppliers and Sourcing Locations

The most apparent and immediate step is to diversify suppliers. Relying on a single vendor or region exposes businesses to concentrated risk. If that supplier experiences a disruption, your entire operation could come to a standstill.

Key tactics include:

Multi-sourcing, instead of single-sourcing critical components, and working with multiple suppliers in different geographical regions.
Nearshoring or onshoring reduces the reliance on distant supply chains by sourcing or producing closer to home.
Qualifying backup suppliers ensures secondary vendors are vetted and capable of ramping up quickly if the primary source fails.

When companies diversify their suppliers, they risk adding complexity and cost in the short term, but it can be a worthwhile investment in avoiding disruptions.

2. Strengthen Supplier Relationships

In addition to spreading risk, companies should be shoring up their relationships with existing suppliers. A collaborative partnership creates shared visibility and faster problem-solving when issues arise.

Effective practices include:

Joint contingency planning means working together to develop backup plans and shared protocols for emergencies.
Shared forecasting and planning provides suppliers with insights into your demand signals and market shifts.
Performance monitoring and feedback is regularly evaluating suppliers’ capabilities, risk profiles, and ability to adapt to changing conditions.

Stronger relationships promote loyalty and prioritization, which are crucial when supply is constrained and everyone is competing for limited inventory.

3. Invest in Supply Chain Visibility

You can’t manage what you can’t see. Real-time visibility across your supply chain is essential for proactive risk mitigation and fast, informed decision-making during a disruption.

How to build visibility:

Digital tracking tools, including IoT sensors, GPS, and cloud-based platforms, track shipments, inventory, and production status.
Integrated data systems break down data silos between procurement, operations, logistics, and sales, providing a complete picture of the supply chain.
Predictive analytics leverages AI and machine learning to forecast potential disruptions and initiate changes before they occur.

These visibility tools can transform a reactive supply chain into a strategic asset. They allow early intervention and more informed resource allocation.

4. Build Inventory Buffers Strategically

While lean inventory models are efficient, they leave little room for error. Resilient supply chains balance efficiency with safety by holding strategic buffers of critical parts, materials, and finished goods.

Smart inventory strategies include:

Risk-based stockpiling, which means your company maintains higher inventory levels for high-risk or long-lead-time items.
Decentralized warehousing signifies distributing inventory across multiple locations to minimize the impact of local disruptions.
Dynamic safety stock uses real-time data and risk scores to adjust safety stock levels as conditions change.

Successful businesses avoid blanket overstocking and focus instead on selective, data-driven inventory planning.

5. Design for Flexibility and Modularity

If you want to improve your company’s ability to pivot during disruptions, product and process flexibility could be the answer. Flexible designs allow you to substitute materials or use interchangeable parts.

Examples of flexible design include:

Modular product architecture: Design products with standardized components that can be sourced from multiple vendors.
Cross-trained teams and facilities: Ensure production and logistics teams can adapt to different tasks, shifts, or locations.
Configurable systems: Invest in systems and machinery that can be reprogrammed or retooled quickly.

This agility not only helps during disruptions but also supports customization, localization, and faster innovation.

6. Adopt Digital Supply Chain Technologies

When companies implement digital transformations they enable supply chain resilience through automated processes and intelligent system utilization. This conversion allows businesses to achieve speed and accuracy while gaining foresight.

These technologies include:

Cloud-based ERP and SCM platforms centralize data, standardize processes, and support remote access and collaboration.
AI and machine learning enable demand forecasting, risk assessment, anomaly detection, and scenario planning.
Blockchain improves traceability and transparency throughout the supply chain tiers.
Robotic process automation (RPA) streamlines routine procurement and logistics tasks.

Digital tools are not just for efficiency. In fact, they are the backbone of adaptability in complex, fast-moving environments.

7. Scenario Planning and Risk Modeling

Resilience requires preparation for the unpredictable. That means stress-testing your supply chain under different “what if” scenarios.

Scenario planning might include:

A natural disaster shutting down a major supplier.
A cyberattack on a logistics platform.
Sudden regulatory changes or tariffs.
A pandemic-related surge in demand.

Companies can uncover vulnerabilities and develop playbooks for rapid response by running simulations and modeling the impacts. Scenario planning prioritizes risk mitigation investments and helps your company avoid scrambling if a crisis occurs.

Check out Relay’s Guide to Emergency Preparedness when it comes to communications here.

8. Develop Crisis Management and Recovery Plans

Even the most resilient supply chains will face disruptions. What matters is how quickly and effectively you can recover. Formalized crisis management plans ensure everyone knows their role when the unexpected occurs.

Best practices include:

Cross-functional crisis teams that include representatives from procurement, operations, legal, finance, and communications.
Clear escalation protocols ensure swift decision-making when time is critical.
Communication plans keep customers, partners, and stakeholders informed and aligned.
Post-mortem reviews assess what worked and what didn’t to improve future responses.

A culture of preparedness reduces downtime and the impact on business operations during a crisis.

9. Focus on Sustainability and Environmental, Social, and Governance (ESG)

Sustainability is a pillar of resilience. Ethical and environmentally responsible supply chains are not just about compliance—they’re often more stable and community-integrated.

Sustainable practices can include:

Sourcing from environmentally and socially responsible suppliers.
Reducing carbon emissions and energy use across the supply chain.
Investing in local communities and talent development.

Stakeholders—from investors to consumers—now expect businesses to operate sustainably. ESG-aligned supply chains are more resilient to regulatory shifts, reputational risks, and long-term resource scarcity.

10. Foster a Resilience Mindset Across the Organization

Resilience isn’t simply a supply chain issue. Instead, it is a company-wide imperative. The organization needs to focus on building adaptability and managing risk throughout all levels from C-suite to frontline staff. To embed a resilience mindset:

Make resilience a board-level priority.
Invest in employee training and cross-functional collaboration.
Encourage innovation and continuous improvement.
Reward proactive risk identification and problem-solving.

The foundation of supply chain resilience exists within organizational culture. Organizations that prioritize flexibility together with foresight and learning capabilities will succeed better in uncertain times.

Final Thoughts

Supply chain disruptions will almost certainly occur in the future, it’s just a matter of when. Businesses that invest in resilience today will weather tomorrow’s storms and gain a competitive edge through faster recovery, stronger supplier relationships, and greater customer trust.

Companies that diversify suppliers, enhance visibility, use technology, and support a culture of adaptability can transform supply chains from a point of vulnerability into a strategic advantage.

Looking for a resilient communication tool with built-in emergency response capabilities and GPS tracking? Learn more about Relay at your own pace in our video demo center.

The post Supply Chain Resilience: How Can Businesses Achieve It? appeared first on Relay.

6 Tips for Increasing Warehouse Safety: Why Communication Matters

Jess Fischer — Thu, 12 Jun 2025 19:28:12 +0000

Warehouses aren’t short of safety hazards – with machinery, production lines, transportation, loading docks, heavy goods, quiet corners, lone working, and tall storage solutions all claiming their own risks.

Better warehouse safety can prevent accidents, boost productivity, and maximize compliance (preventing costly fines). The question is, how do you improve warehouse safety in the best, most tangible way?

In this article, we’ll share best-practice tips for increasing warehouse safety, and what to look for in a warehouse radio to improve safety, efficiency, and productivity.

Tips for Increasing Warehouse Safety

Warehouses are critical working environments. Speed, precision, and teamwork are paramount to streamlining operations and maximizing productivity.

Incorporating safety into these fast-paced environments is crucial (with the second-highest fatality rate of all US sectors), but it isn’t always easy.

Top tips to increase warehouse safety include:

1. Facilitate clear, critical communication

Warehouse safety is rooted in strong, efficient team communication. Without it, people, teams, processes, and even customers can suffer.

One of the best ways to ensure good communication in a workplace is to deploy a secure, reliable communication device (i.e., a walkie-talkie or radio).

Good communication in warehouses can result in:

Safer and engaged staff: Research finds “disengaged” staff are involved in 64% more workplace accidents compared to “engaged” workers.
Helps build cohesion and team morale: Safety is everyone’s responsibility, and better communication can lead to better teamwork and a sense of shared ownership over safety practices.
Increased productivity: A 2017 study found that staff who feel safer at work are more productive and put more effort into their jobs.
Better compliance: OSHA communication standards for warehouses have financial penalties for non-compliance. Clear procedures and workflows support compliance during inspections and routine business operations.

2. Minimize “deadzones”

Lone workers face the same risks as group-working employees, but research shows that working alone increases the likelihood of an accident and the severity of the outcome.

Communication deadzones (areas with no signal) can be a real problem in a warehouse. For example, areas with bad or no signal can include outdoor areas, behind tall shelving units, quiet corners, or inside small storage rooms.

For lone workers, this creates a potential safety hazard. If an incident happens, getting fast help can reduce the likelihood of a serious injury. A dead zone can prevent workers from getting the help they need quickly – if at all.

To improve warehouse safety, a communication system with triple-redundancy (like Relay’s smart radios) minimizes deadzones. By intelligently transitioning between Wi-Fi and cellular networks, it maximizes connectivity and reduces downtime.

3. Be emergency-ready

In 2023, 11.7 per 100,000 deaths in the US warehousing and transportation sector were deemed “preventable”. Ensuring your warehouse is emergency-ready can help reduce the likelihood of preventable workplace deaths and injuries.

Ways to be emergency-ready include:

Using digital solutions to establish clear communication lines in emergencies, e.g., through localized messaging, team alerts, and company-wide alarms to ensure messages reach the right people at the right time, without causing unnecessary panic
Running emergency drills (read how to manage emergency evacuations using radios)
Deploying signage to display emergency protocols
Delivering bite-sized training on critical situation procedures

Check out Relay’s Guide to Emergency Preparedness here.

4. Develop (and implement) proper safety protocols

Warehouses must develop sufficient safety protocols to protect staff against hazards and comply with regulations. These safety protocols must be suitable for use in practice and contain clear, actionable practices that can be easily adhered to.

Some examples of how safety protocols can be implemented include:

Leveraging digital tools to track preventative maintenance, issue reminders, facilitate communication, and manage critical alerts
Conducting pre-use inspections on machinery or production line equipment as a standard, daily practice, or during handovers
Running routine safety briefings on risks, hazards, and procedures
Facilitating good communication to create team cohesion and a shared ownership of risks
Practicing good organization and housekeeping through specific, actionable, and clearly assigned clean-up tasks

5. Create space for anonymous reporting

Stats report that 85-98% of accidents are caused by the unsafe acts of employees, and that unsafe acts cause four times as many accidents and injuries as unsafe conditions.

Supervisors don’t have eyes and ears everywhere – but employees do. Not everyone is willing to speak up if they see poor practice, especially if the person is more senior than them.

Creating an anonymous tip line allows staff to report poor practice when they see it, without worrying about negative repercussions from their colleagues or managers.

Digital forms can be a good tool, along with a good old-fashioned post-box situated in a relatively remote location (like outside the toilets or away from any interior security cameras).

6. Address language barriers

One in four safety incidents in the workplace are linked to language barriers. In multi-lingual teams, miscommunication can cause delays, safety risks, and costly inefficiencies (we’ve found that language barriers drain $500,000 from businesses each year).

Advances in business technology (like Relay’s TeamTranslate™) can prevent communication breakdowns and minimize safety risks caused by misunderstandings.

What to Look For in a Warehouse Radio to Promote Safety

A two-way radio can facilitate workplace safety, but it’s important to choose the right radio for a warehouse. Warehouses are known for efficiency, structured workflows, and fast-paced working procedures, so a radio must cater to very specific needs for a business to realize benefits.

Here are the key features to look for in a warehouse radio:

Instant alerts: Every second matters in an emergency. Relay works faster than other radios in the industry, ensuring your alerts are delivered in less than one second, with no delays.
Clear, crisp two-way communication: A radio should minimize misunderstandings through clear radio signals in any location.
Triple-redundancy coverage: Deadzones in remote locations or quiet warehouse corners can pose safety risks. Radios with triple redundancy ensure continuous connectivity.
Targeted messaging: Sending alerts to everyone can cause confusion. Devices with tailored workflows ensure messaging only reaches those who need it.
Lone worker/man-down alarms: A complete panic alert system promotes safety in the workplace, helping staff report a dangerous malfunction, fires, health concerns, or a personal accident.
Loud vs vibrate alarms: Not all alarms need volume. Sounding alerts can cause unnecessary chaos. Choose a device with the option for loud and vibration alarms to prevent distractions and panic.
Real-time language translation: Miscommunication can cause accidents. Avoid misunderstandings with a live language translator built into your warehouse radio.

Live location tracking: Enabling leaders to precisely track employee locations indoors and outdoors through location beacons.
Legislative compliance: Radios that meet legislative requirements in multiple regions guarantee satisfaction with legal mandates.
Customization and workflow management: Devices with a cloud-based dashboard enable administrators to adapt workflows to maximize safety and efficiency easily.
Durability: A radio must be strong enough to withstand drops and falls in a warehouse. Relay is MIL-STD 810H certified (meaning it can withstand shock, vibration, and extreme temperatures) and IP-68 certified (for water and dust resistance). Learn more about Relay’s Class 1 Division 2 Certified devices.

Read our ultimate guide on choosing the best radio for a warehouse.

Replace Your Two-Way Radios With Relay

Bridging the gaps between people and processes, Relay is a communications device built for the future.

Our radios offer durability, reliable connectivity, and customizable workflows to maximize safety, efficiency, and productivity in a warehouse environment.

Watch our on-demand videos to discover how Relay radios work for warehouses, or book a live demo with our expert team today for a tailored chat about your specific business needs.

Ready to get started? Explore pricing to find the best solution for you.

The post 6 Tips for Increasing Warehouse Safety: Why Communication Matters appeared first on Relay.