The Lack of Skilled Process Operations Labor: How Process Automation and Control Helps

Manufacturing in the U.S. faces a serious labor issue. Over 600,000 positions are currently unfilled. By 2033, that number could rise to 1.9 million. Nearly 60 percent of manufacturers say they cannot attract or keep enough employees. We hear the same concerns from our customers. They need systems that support their workforce, not replace them, but make it possible to do more with fewer hands.

Process automation and control helps companies maintain output even when labor is tight. By automating repetitive tasks, like batching or ingredient weighing, we allow teams to focus on jobs that need judgment or troubleshooting.

Our automation systems can manage complex operations with precision. We customize controls to match your equipment, whether you are blending, grinding, or handling bulk material. This allows a smaller crew to keep operations running smoothly with fewer errors.

Batching is one area where automation makes an immediate impact. Our batching systems are built to reduce the risk of missed ingredients, incorrect weights, or poor documentation. These systems are easy to scale and expand as needed. They support micro, minor, and major ingredient batching using accurate controls and real-time data tracking.

That kind of precision not only improves product quality. It also allows you to train fewer people to manage more process steps.

We know that manufacturing processes vary across sectors. From agriculture to food processing to industrial processing, our experience helps us build systems that match your application. Whether you are moving powders, liquids, or mixed ingredients, we develop process controls that make your operations easier to run and easier to maintain.

We also provide process controls and automation that can upgrade existing systems or launch new production lines. Our control panels, software, and user interfaces are all designed with simplicity and reliability in mind.

No automation system runs on its own. We make sure your team understands how to operate and troubleshoot your systems. Our engineers handle software, mechanical, and electrical setup. We also stay available for support after startup.

Because we build custom solutions, our systems do not come with generic instruction manuals. Instead, your team gets to work with engineers who know your project from start to finish. This hands-on approach reduces downtime and builds confidence in your operations.

Companies who adapt to the labor shortage with process automation and control will be more resilient. They will rely less on hard-to-find labor and be better prepared for future demand shifts. If your facility is ready to make a change, we are here to help. You can request a quote today to start the conversation.

• As of January 2024, there were approximately 622,000 unfilled manufacturing positions in the United States (source: uschamber.com).
• From 2024 to 2033, the manufacturing industry is projected to need 3.8 million new workers, but 1.9 million jobs may remain unfilled due to ongoing labor shortages (source: supplychaindive.com).
• Nearly 60% of manufacturers cite the inability to attract and retain employees as their top challenge (source: deloitte.com).
• About 15% of manufacturing workers report a skills mismatch, showing a gap between available skills and job requirements (source: weforum.org).
• 81% of manufacturers say high turnover has disrupted operations, and 78% report decreased productivity due to workforce shortages (source: ohsonline.com).