This month in Modern: MRO emerges in materials handling

A couple years ago, executive editor Bob Trebilcock launched a series of articles that we now call “The Big Picture.” These in-depth features allow our coverage to fly at 30,000 feet above the day-to-day operations, offering Modern readers a better view of how materials handling products, systems and best practices are making an impact on the evolution of global business.

So far in this series, Trebilcock has defined “big data” in context of improving warehouse and DC management; detailed materials handling’s role in the rebirth of manufacturing; presented a grounded, honest look at where robotics fit into our processes; and offered the most comprehensive assessment of automation’s role in the growth of e-commerce and the resulting omni-channel fulfillment challenge that’s now pushing companies to overhaul their operations.

These Big Picture articles complement our System Reports, as they share a broad assortment of sources and insight on topics that are driving readers to make the changes we detail in our cover story case studies.

This month in Modern, Trebilcock gives us his next Big Picture, one that represents a logical progression based on automation’s unmistakable importance in our new world. He digs into the emerging best practice of maintenance, repair and overhaul (MRO) in materials handling.

Routinely defined as the best practice of “retaining or restoring an item in or to a state in which it can perform its required function,” MRO is second nature in the aviation and heavy equipment business and, according to Trebilcock, will quickly become every bit as important to end users as the technology they choose for their systems.

“As automated systems have become more prevalent and more complex, automation providers are now competing on their maintenance offerings,” says Trebilcock. “But more importantly, their customers are now demanding it. In fact, the provider’s service manager is now likely to be part of the initial sales presentation.”

Clearly driving this new level of interest in MRO is the increasing complexity in today’s software-driven systems, especially inside more sophisticated e-commerce, grocery and beverage facilities. Uptime of these “smart” systems is clearly more vital than ever before—and in many cases, it’s the foundation on which the business rests.

“When a conventional materials handling system goes down, the repair is often mechanical and can often be kept running with a manual system until a motor is swapped out or a conveyor belt is replaced,” says Trebilcock. “If the software or controls fail in one of today’s highly automated systems, the whole system is likely to be down until the problem is isolated. It could be mechanical, it could be software, or it could be a sensor.”

Enter our heightened need to understand and put MRO practices in place. However, finding the skilled technicians is another challenge, considering that most DC maintenance staff currently lacks this level of technical skill known as “mechatronics.”

“The ‘people component’ is the next big challenge,” adds Trebilcock. “Keeping these systems up and running requires a pool of trained technicians that are in short supply. MRO has emerged, but it will be important for the industry to help in the development of the people who will keep our complex, innovative organizations working.”