As Digi-Key’s business expanded, its Fargo warehouse—originally intended for slower-moving inventory—faced growing operational challenges. The facility’s used conveyor system, initially configured with a basic start/stop button, struggled to handle increased package volumes, often causing backups, crushed items, and fallen parcels that required constant staff monitoring.
From Manual to Automated Control
Joey Mulqueen, Digi-Key’s Automation Product Manager, assessed the problem and implemented a sensor-based solution. By installing two Banner Engineering QS30VR3LP photoeyes 20 feet apart, he created a system where the conveyor stops only when both sensors detect a package—preventing jams while eliminating the need for manual oversight.
How the New System Works
The upgraded setup uses Lite On sensor technology to detect packages sequentially. The conveyor continues running when only one sensor is triggered but stops when both are activated, resuming automatically once the package is cleared. This innovation optimizes workflow and frees staff for higher-value tasks.
Scaling Up for Future Growth
The automation upgrade not only resolves immediate inefficiencies but also prepares the Fargo facility for Digi-Key’s continued expansion. By replacing reactive manual controls with intelligent sensing, the company ensures smoother operations as order volumes rise.
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