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Case Studies

See the impact of our Plant Floor Certified Solutions

Discover real-world applications of our solutions that have transformed manufacturing operations

HP/FedEx Kiosk

Modular designed, manufactured, and delivered in quantity since 2013

Modular designed, manufactured, and delivered in quantity since 2013

The Story: In the year 2013, FedEx Freight had to replace approximately 10,000 Operator Interface computers in over 350 North American distribution centers. HP Inc., FedEx’s strategic computer and computer peripheral supplier/partner, determined that FedEx could achieve the same functionality of the computer (running Windows) by using ThinClient technology. ThinClients had a lower per unit cost and considerably lower maintenance costs due to not having to maintain and support OS and Disc requirements at the depots. Depots, which typically do not have IS support, could operate the ThinClient in the cloud, taking advantage of its ability to be maintained and supported remotely.
 
The Challenge:
  • Reliable functionality of touchscreen and ThinClient in loading dock environment with ambient temperatures reaching up to 110⁰F
  • Waterproof touchscreen technology required
  • Easy and reliable access to required interconnects such as data, power, and barcode scanners
  • Able to use existing industrial PC mounting systems that were already installed
  • Ease of touchscreen and ThinClient maintenance
  •  
The Solution:
  • A powder coated aluminum kiosk enclosure that incorporates a 12.5” fully sealed touchscreen display with room for the ThinClient and a NEMA 4/12 rated environmental seal
  • Power supplies for both the ThinClient and the display are outside and separate to drastically reduce the heat rise and ambient temperature inside the enclosure
  • Ruggedized sealed touchscreen display
  • Sealed cable glands for all interconnects
  • Mounting pattern specifically designed for pre-existing installation brackets
  • ThinClient and touchscreen mounts designed for simple removal/replacement facilitating field maintenance and repair when required
The Results:
 
HP vigorously tested Modular’s design in their environmental testing facilities and proved the enclosure was up to the task. In 2013 they began deployment of the new ThinClient kiosks protected by Modular enclosures in FedEx’s North American depots. These units worked reliably at about 1/3 the cost of the previously installed PC units for a decade. In 2023, pleased with the longevity and cost effectiveness of the first wave of kiosks, HP once again partnered with Modular to update all of their FedEx Freight kiosks to accommodate the current ThinClient design while still using the existing mounting system.
The Challenge:
  • Reliable functionality of touchscreen and ThinClient in loading dock environment with ambient temperatures reaching up to 110⁰F
  • Waterproof touchscreen technology required
  • Easy and reliable access to required interconnects such as data, power, and barcode scanners
  • Able to use existing industrial PC mounting systems that were already installed
  • Ease of touchscreen and ThinClient maintenance

The Solution:
  • A powder coated aluminum kiosk enclosure that incorporates a 12.5” fully sealed touchscreen display with room for the ThinClient and a NEMA 4/12 rated environmental seal
  • Power supplies for both the ThinClient and the display are outside and separate to drastically reduce the heat rise and ambient temperature inside the enclosure
  • Ruggedized sealed touchscreen display
  • Sealed cable glands for all interconnects
  • Mounting pattern specifically designed for pre-existing installation brackets
  • ThinClient and touchscreen mounts designed for simple removal/replacement facilitating field maintenance and repair when required
The Results: HP vigorously tested Modular’s design in their environmental testing facilities and proved the enclosure was up to the task. In 2013 they began deployment of the new ThinClient kiosks protected by Modular enclosures in FedEx’s North American depots. These units worked reliably at about 1/3 the cost of the previously installed PC units for a decade. In 2023, pleased with the longevity and cost effectiveness of the first wave of kiosks, HP once again partnered with Modular to update all of their FedEx Freight kiosks to accommodate the current ThinClient design while still using the existing mounting system.

Kraft Foods

Food/Beverage/Meat/Poultry

The Story: In the 1990s, Kraft General Foods (now Kraft Heinz Co.) was rethinking running their business entirely via pencil and paper on a clipboard. They envisioned the efficiency they could achieve by running SAP in real-time within their processing areas. With the rise of the multi-user, multi-tasking OS that is the basis of all computing technology today, Kraft saw an opportunity to outpace their competitors by computerizing their production scheduling, recipe management and quality assurance applications. Hewlett Packard (HP, Inc.) was brought on to provide their X-Terminal and PC products. They teamed with applications software providers to meet Kraft’s technological needs and chose Modular to protect it all with integrated display/computing workstations meeting NEMA 4X rating requirements.

The Results:

The long-term reliability of Modular’s workstations solidified an ongoing relationship with both HP and Kraft. 30 years later, Modular still supplies Kraft with HP Inc. Workstations as well as a host of other technologies, including Large Panel Displays, Printer Enclosures, Instrumentation Enclosures and Custom Enclosures for use in their food and beverage processing operations.
Kraft’s example of applying computerized technology to one of the largest Food Processing/Manufacturing Companies in the United States was followed by other giants in the industry, resulting in computerization becoming integral to success in the industry.

The Challenge:

  • Pioneering the deployment of reliable computing technology in an environment that regularly requires sanitation washdowns
  •  Ensuring workstation designs facilitated the eventual need for maintenance and technological upgrades
  • Devising safe and simple mounting solutions that meet the localized challenges of installing workstations where needed on the plant floor

 

The Solution: 

  • Polished Stainless Steel NEMA 4X enclosures with durable viewscreens and a keyboard valet for keyboard and mouse
  • Simple lift-off door hinges promote ease of maintenance and replacement
  •  Rain guttered door frame design prevents water from running into the enclosure when the door is opened
  • Compression latches create a reliable seal against door gaskets
  • Sealed cable glands for all interconnects
  • PC and monitor mounts designed for simple removal/replacement to facilitate field maintenance and repair when required
  • Various mounting solutions allow the workstations to be attached to walls, installed on pedestals fixed to the plant floor, or rolling carts for temporary station set-ups when necessary

The Results:

The long-term reliability of Modular’s workstations solidified an ongoing relationship with both HP and Kraft. 30 years later, Modular still supplies Kraft with HP Inc. Workstations as well as a host of other technologies, including Large Panel Displays, Printer Enclosures, Instrumentation Enclosures and Custom Enclosures for use in their food and beverage processing operations.
Kraft’s example of applying computerized technology to one of the largest Food Processing/Manufacturing Companies in the United States was followed by other giants in the industry, resulting in computerization becoming integral to success in the industry.

Ford Motor Company

Automotive

The Story:

In 1994, the Ford Motor Company approached Modular to design and manufacture a NEMA 12 rated standup enclosure with a very particular list of requirements. This enclosure was to house a 19” display, a printer, a keyboard/mouse and an IBM Industrial PC. In addition, the enclosure required integrated surge protection, shelving to accommodate additional instrumentation and PLC components as necessary, and must remain completely secure with all openings covered by lockable doors. Ford already had a design and pricing from an incumbent supplier, but were shopping for something more affordable and, perhaps, better suited to their needs.

The Results:

Ford chose Modular to deliver systems to one of their plants, saving them over $100,000 in initial deployments, and the Modular solution became the standard at all Ford North American facilities. Over the years, Modular has become the de facto standard for NEMA 4 17”/19”/21.5” HMI workstations, with and without touchscreen capabilities, along with NEMA 4X outdoor workstations and NEMA 4 indoor/outdoor large screen displays.

The Challenge:

  • Reliable functionality of a NEMA 12 rated large cabinet enclosure to house several different technologies without any interfering with the function of the others
  • Temperature management to prevent the combined ambient heat rise of multiple machines from impacting performance
  • Power distribution large enough to handle the electrical load of multiple machines running simultaneously that also includes the appropriate amount of surge protection
  • Cord management to organize and contain the wiring of multiple machines to prevent damage and tangling
  • All openings must be lockable via either padlock or key
  • Versatility in interior layout to accommodate ease of printer access and varying shelf heights required by potential new equipment
  • Ensure workstation design facilitates the eventual need for maintenance and technological upgrades

The Solution:

  • A NEMA 12 rated upright steel cabinet standing 63” tall with inside and outside powder coat epoxy finish, a keyboard/mouse tray, 3 interior shelves, and a field-replaceable durable monitor window able to operate reliably in ambient temperatures up to 90⁰
  • Internal air circulation fan prevents “hot spots” caused by multiple machines in an enclosed area
  • A load-appropriate electrical power distribution panel that includes an A-B circuit breaker, a din rail, terminal blocks and a multi-plug surge protector
  • Panduit cable routing
  • Multiple door latches per door that are key lockable
  • One shelf slides out while two remain fixed via adjustable 19” rack mount design
  • Doors mounted on both sides of the cabinet allow both full front and back access, while simple lift-off door hinges promote ease of maintenance and replacement
  • PC and monitor mounts designed for simple removal/replacement facilitate field maintenance and repair when required

Lonza Group

Pharmaceutical

The Story:
Lonza Inc., a multinational pharmaceutical manufacturing company, required 21” touchscreen display workstations in some of their North American facilities. In addition to standard pharmaceutical product requirements, such as polished 316 stainless steel surfaces for ease of cleaning and sanitation and gasketing that is impervious to harsh cleaning solvents, Lonza wanted mobile workstations that would transition smoothly between stations and other product manufacturing areas.

The Results:
Modular provided a cost-effective solution that exceeded Lonza’s specification requirements, establishing a supplier/partner relationship that resulted in Modular providing not only this solution to various facilities but also developing and providing fixed workstation solutions incorporating 21” and 24” touchscreen workstation products for both NEMA 4X environments and hazardous area Class I, Division 1 and Division 2 production environments as well.

The Challenge:

  • Reliable functionality of mobile workstation for NEMA 4X environment that meets standard pharmaceutical product requirements 
  • Must operate for a minimum of 4hrs via battery backup technology
  • Simultaneous operation of dual displays
  • Must have waterproof and chemical resistant external speakers
  •  Must have reliable external LAN wireless capability
  • Must have integral NEMA 4X keyboards and pointers
  •  Ensure workstation design facilitates the eventual need for maintenance and
    technological upgrades

The Solution:
A polished 316 stainless steel cabinet with 4 FDA approved locking casters, knife-edge door seals with closed cell silicone gaskets, internal hinges, sloped top to prevent water pooling, and cable glands for USB cable routing

  • Internal power distribution for all components as well as 120-volt, 600-watt, UPS with battery backup
  • Dual projective capacitive touchscreens behind sealed Lexan windows
  • USB powered external voice speaker that is both waterproof and chemical resistant
  • Internal cooling fan to prevent heat buildup resulting from multiple machines running in an enclosed environment
  • Sealed external wireless LAN kit
  • Ergonomically designed enclosure ensuring OSHA keyboard/pointer access with a bonus NEMA 4X external on/off power switch and quick disconnect connections for maximum ease when relocating unit
  • Dual rear door access as well as dual front door access, designed to facilitate simple removal/replacement of equipment for maintenance and repair when required, with multiple keyed access latches

Across the US for 30+ years

Additional plants where Modular solutions can be found