**California:** Zira is transforming pallet production by deploying AI Vision and telematics to improve lumber yield, reduce downtime, enhance energy efficiency, and bolster sustainability. Originating from a major industrial research project, Zira’s technology offers real-time operational insights that streamline manufacturing and set new standards for the sector.
In the rapidly evolving landscape of manufacturing, the pallet industry is witnessing a significant shift towards smarter operations driven by technological advancements. Zira, a company based in California, is at the forefront of this transformation, harnessing the power of artificial intelligence (AI) and telematics to enhance productivity and sustainability in pallet production. Their guiding principle, “Work like it’s 2050,” reflects a commitment to modernising factory operations today.
Zira employs AI Vision technology to improve various operational metrics such as lumber yield, production accounting, and energy efficiency. The company combines telecommunications and informatics to create a telematics solution that allows for remote monitoring and control of manufacturing assets. This innovation enables manufacturers to receive real-time data for immediate performance evaluation and troubleshooting, significantly enhancing decision-making processes.
Elhay Farkash, CEO of Zira, elaborated on the origins of the company during an interview with Pallet Enterprise. Starting as an industrial research project funded by MIT, UC Berkeley, and the University of Chicago, Zira aimed to address energy management issues within industrial settings. The project achieved a 17% improvement in energy consumption through real-time data analysis. Recognising the parallel challenges within the pallet industry, Zira pivoted its focus to optimize operations in pallet manufacturing.
A crucial finding for Zira was that addressing energy conservation in factories often hinged on maximizing machinery uptime. “If you want to save energy in a factory, you’ve got to focus on uptime,” Farkash stated. By implementing their platform, Zira has successfully reduced downtime related to forklift operations, which can account for as much as 80% of delays in some facilities. For instance, the system sends alerts to forklift drivers before congestion occurs, maintaining continuous workflow.
Beyond operational efficiency, Zira’s technology supports sustainability initiatives by providing insights into energy usage and waste production. The company’s platform monitors various sustainability metrics, enabling pallet manufacturers to comply more effectively with environmental regulations. “For pallet companies, our technology helps tackle sustainability and environmental requirements in a practical way,” Farkash noted. Detailed reports generated by Zira assist companies in identifying waste sources and optimising processes for reduced environmental impact.
Zira has collaborated with several notable companies in the pallet sector, including Millwood, utilising its “Live Cut” Solution to enhance lumber yield. This technology leverages AI cameras and advanced vision telematics to analyze each log as it enters the processing line, providing operators with optimal cutting patterns in real time. The successful implementation of this solution resulted in considerable returns on investment for Millwood.
The system also plays a critical role in training, highlighting operational inefficiencies and suggesting corrective actions in real time. This proactive approach aids in the development of a skilled workforce. Furthermore, Zira’s AI Vision technology incorporates quality control measures, automatically detecting flaws in pallets, such as cracks or incorrect dimensions, significantly reducing the need for additional labour.
Among the primary applications Zira serves in the pallet industry are the dismantling and repair processes, as well as logistics monitoring through trailer tracking systems. Each of these applications has been designed to streamline operations, thereby providing a comprehensive overview of production efficiency.
As Zira continues to expand its capabilities, the company plans to integrate 3D and 4D technologies into its AI Vision system, enhancing measurement and data interpretation further. Farkash expressed optimism about the growth potential of AI in manufacturing: “Every image frame processed improves our models, giving us a competitive edge in the field.”
In summarising the essence of Zira’s vision, Farkash stated that working like it is 2050 means leveraging real-time insights that were once the domain of large, complex systems, now accessible through a simple installation of cameras and cloud data streaming. This agility allows companies to make informed decisions and take action in near real-time, something he believes will redefine operational intelligence in manufacturing.
Zira represents a significant shift in how technology can enhance the traditional pallet manufacturing process, bringing a future-oriented mindset to a critical segment of the supply chain. With its commitment to innovation and efficiency, Zira is setting a benchmark for the pallet factories of the future, demonstrating that advanced technologies can deliver tangible benefits in today’s industrial landscape.
Source: Noah Wire Services
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