The Workforce Challenge in Manufacturing
Employee recruitment and retention have always been hot topics for food manufacturers and packagers. This has grown worse as the workforce has shifted toward less skilled labor since the COVID-19 pandemic. According to the PMMI 2024 State of the Industry report, the shortage of skilled workers is one of the key challenges across the packaging industry. A recent study conducted by Deloitte and The Manufacturing Institute found that 65% of manufacturers cite talent acquisition/retention as a top challenge. Many manufacturers are left wondering how to address the problem. Increasing automation is one solution in industrial weighing and automation.
Automation as a Solution to Labor Shortages
Put simply, increasing automation decreases the number of operators needed to complete the same amount of work. As labor shortages have increased, PMMI has found that this is true in reverse as well. The reduction in available labor has driven an increase in the demand for automated packaging solutions.
Investing in industrial weighing automation systems goes beyond the investment in multihead weighers, tray fillers, and checkweighers to improve productivity. Investing in automated packaging machines includes identifying the right equipment that will reduce the reliance on skilled manual processes. The reduction of manual processes minimizes the chance for operator error.
The Power of User-Friendly Design
Machine design that takes the operator into account makes it easier to train and retain operators. PMMI insights reveal that simplified Human-Machine Interfaces (HMI) have been on the rise. There are multiple design features that can be incorporated into HMIs to benefit operators.
One key feature that aids operators in today’s workforce is intuitive, app-like navigation. Visual prompts, icons, and picture-based troubleshooting make maintenance and remote support easier than ever. Multi-language-supported HMIs enable operators to run machines in their native languages. Safety and mistake-proofing features such as lockout systems further reduce the risk of operator error.
Automating Weighing, Filling, and Inspecting Solutions from Yamato
As the leader in weighing technology for food packaging, Yamato Dataweigh™ combination scales offer high accuracy and speed to enhance packaging productivity and improve bottom line. These multihead weighers also feature automated systems and processes to meet the needs of today’s workforce and increase workforce sustainability.
The HMI of DataweighTM scales can store up to 300 unique recipes. This means that operators do not need to manually re-enter the information every time, reducing the possibility of operator error. Additional features in our industrial weighing automation system include auto tuning of the linear feed pans, automatic feed controls to optimize product feed, and auto zero of the weigh buckets to account for product build up during production.
Yamato’s tray-filling machines work in tandem with DataweighTM combination scales to produce a fully automated weighing and filling machine system. Yamato offers two different types of automatic tray-filling packaging machines, the Automatic Diving Funnel (ADF) and the Multi-Point Depositor (MPD).
Yamato checkweighers ensure impeccable quality. These in-line inspection systems feature intuitive HMI programming. To further increase operational efficiency through automation and reduce the need for manual intervention, Yamato checkweighers can provide real-time feedback to select DataweighTM scale models. This automatically updates the weighments at the scale based on checkweigher feedback.
Empowering Operators Through Comprehensive Training Programs
Investing in training while facing high turnover rates may seem counterintuitive. However, research by Deloitte and The Manufacturing Institute found that employees are 2.7x less likely to leave if they feel they can gain skills needed for the future. An investment in training is an investment in employee retention.
Yamato has developed several training options to support manufacturers in overcoming the growing skills gap. These comprehensive training programs are designed to equip operators with the necessary skills to effectively use and maintain Yamato-designed automated packaging equipment. Training can be held at a Yamato Technology Center or at a customer facility.
Training programs are tailored to the needs of the customer, but one of the most popular programs is the three-day, on-site training program. On the first day of training, a Yamato instructor will review basic scale operation and how to get the best possible operation with any product. On the second day of training, the focus shifts to basic maintenance and preventative maintenance. The third day of training focuses on advanced applications and addressing all remaining questions. These training initiatives not only enhance operational efficiency but also contribute to employee retention by fostering a knowledgeable and confident workforce.
Case Study: Radienz Living and Yamato Corporation
A real-word example can shed light on how automation, intuitive design, quality service, and training can improve packaging operations. In January 2025, Radienz Living installed a Yamato Omega Series DataweighTM Scale. This scale was selected to provide an automated solution to the problem of product (detergent pod) build-up on the scale.
One key consideration in choosing to work with Yamato was the easy-to-use HMI screen. The intuitive design was complimented by quality training from Ron Gartner, Field Service Technician, during the installation process. “Ron took the time to explain each setting found on the HMI. Great guy!” said Ivan Delgadillo, Project Engineer for Radienz Living. The outcome of this training was better understanding of settings, smoother onboarding, improved performance.
Since investing in the Omega Series scale, Radienz Living has seen a positive impact on their business. The packaging line now has consistent output. Another positive benefit has been the automated integration with their Yamato checkweigher.
A Smarter Workforce Starts with Smarter Machines
The future of manufacturing depends on adapting to the realities of today’s labor market. By instituting automated processes and investing in packaging lines that incorporate automation and intuitive design, companies are setting their teams up for success. These employees are more resilient, trainable, and engaged. Yamato Corporation is leading the way, not just in technology—but by being a supportive partner throughout transition to greater automation with industrial automation weighing systems.
Looking to upgrade your line with equipment designed for today’s workforce? Explore Yamato’s solutions for weighing, filling, and inspecting. Contact us for more information on how increasing automation can improve your operational efficiency.