Automation and the Reshoring Trend -
A Decade in the Making

Automation has led to numerous opportunities for manufacturers, resulting in the growing trend of reshoring over the past decade.

Harry Moser established the Reshoring Initiative in 2010, a non-profit aimed at bringing manufacturing jobs back to the U.S. by providing tools to reduce costs through local production. PTA Plastics previously explored why companies choose to reshore, including the need to address global supply chain challenges and meet consumer demand for “Made in the USA” products. Bank of America’s research indicates that companies were already transitioning to reshoring initiatives before the COVID-19 pandemic, and the global supply chain disruptions only expedited this process.

Many companies initially chose offshore manufacturing due to lower labor costs, resulting in cheaper production. Despite this, automation has been instrumental in facilitating companies’ return to their home countries over the past decade or so. Reshoring involves more than just relocating a project. PTA Plastics and the Plastics Industry Association (PIA) professionals discussed reshoring challenges in a virtual roundtable.

Automation has not only made reshoring possible but has also greatly influenced how industries are progressing. PTA Plastics acknowledges the significance of automation in ensuring repeatable processes, excellent quality, and cost efficiency, and is fully committed to this effort.

Innovation and Automation at PTA Plastics

U.S. companies had to find creative solutions to match the cost advantage of low-cost labor in offshore markets without reducing wages. PTA Plastics has recognized the potential of automation and invested significantly in alternative solutions to automate our processes over the past 12+ years. Starting in 2008, PTA Plastics emphasized the full utilization of Yushin robots as End of Arm Tooling (EOAT). PTA has implemented automation in processes like in-mold decorating, insert placement, part pick and place, and multi-clip applications. The end customer benefits from these investments and increased automation processes, as it leads to cost-effective solutions through labor savings. By freeing up a half operator’s time for three or more operators, not only is money saved, but the operators can also allocate their time and attention elsewhere.

By recognizing the potential savings in jobs with repetitive tasks, PTA Plastics has embraced automation and moved towards Industry 4.0. One of our cobots is being used to develop an application for automating laser scanning of parts. With this automation, an in-process inspection and a First Article Inspection Report (FAIR) can happen at the same time. As businesses flourish and adapt, the automation of complex tasks will become increasingly prevalent.