Have you ever faced frustrating session drops that disrupt your warehouse operations?

In manufacturing, every second counts, and unreliable connectivity can lead to costly inefficiencies. One major challenge manufacturers face is maintaining seamless connectivity between mobile devices and back-end systems in warehouses and production environments.

That’s where StayLinked, a modern terminal emulation (TE) solution, comes in.

As a company with deep expertise in warehouse and manufacturing automation, we often recommend StayLinked to our customers because it is a robust, secure, and high-performance solution. By leveraging StayLinked, you can eliminate session drops, enhance system performance, and ensure seamless workflow operations.

What is StayLinked?

StayLinked is an advanced terminal emulation software designed specifically to keep mobile workers connected to host systems without disruptions. Unlike traditional TE solutions that rely on legacy architectures prone to session losses, StayLinked uses a server-based architecture that ensures uninterrupted connections, even in challenging network environments like that of a warehouse.

With StayLinked, manufacturers can modernize their existing green screen applications without replacing their entire backend infrastructure. The software is designed to work seamlessly with the latest Android mobile computers, barcode scanners, and industrial handheld devices (like the CK67 Rugged Mobile Computer from Honeywell, for example), providing a future-proof solution for manufacturing operations.

Why StayLinked in the Warehouse

1. Uninterrupted Connectivity
Dropped connections can bring warehouse operations to a standstill, causing delays, inefficiencies, and frustration among workers. StayLinked eliminates this issue by maintaining persistent sessions even when network disruptions occur. This means that workers can move between different areas of the facility without losing their place in a transaction or re-entering data.

2. Improved Performance and Speed
Traditional terminal emulation solutions can introduce latency, making it difficult for workers to interact with host systems efficiently. StayLinked optimizes data transfer, ensuring lightning-fast response times. This is particularly crucial in high-speed manufacturing environments where real-time data is essential for production schedules, order fulfillment, and inventory tracking.

3. Seamless Integration with Legacy Systems
Many manufacturers rely on long-established warehouse management and enterprise resource planning (ERP) systems. Replacing these systems can be costly and disruptive. StayLinked allows companies to modernize without ripping and replacing existing infrastructure. It integrates smoothly with Windows-based, Unix, and IBM AS/400 systems, extending their lifespan while providing a modern user experience.
 
4. Enhanced Security
Security is a growing concern for manufacturers handling sensitive production and supply chain data. StayLinked enhances security by centralizing TE session management on a secure server, reducing the risk of unauthorized access. Additionally, encrypted communications ensure that sensitive data remains protected from cyber threats.

5. Future-Proofing Operations
With the rise of Android-based mobile devices in manufacturing, businesses need a TE solution that adapts to modern hardware. StayLinked not only supports these new devices but also offers features like SmartTE, which converts traditional green screens into a more intuitive, touchscreen-friendly interface. This enhances user experience and reduces training time for new employees.
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​Our Expertise with StayLinked
At IMS, we specialize in helping manufacturers integrate and optimize mobile solutions for warehouse and production environments. Our team has extensive experience deploying StayLinked for a wide range of manufacturing applications, ensuring seamless implementation, improved operational efficiency, and long-term success for our clients.

One customer that had yet to migrate to Android received complaints from users about stalled and dropped telnet connections.  We deployed StayLinked as part of the upgrade solution, and the net effect was a boost in productivity and reduction in lost time due to the elimination of system interruptions. 

The built-in capabilities of StayLinked were an added benefit; in this case, our customer was able to refactor their old green-screen interface into a more modern interface for more intuitive operation and greater accuracy.

Contact us today to learn more about Staylinked. At IMS, we take a consultative approach to every project, ensuring that you get the right setup, configuration, and ongoing support needed to maximize StayLinked’s benefits.

If you’ve ever had to print labels in a production environment, you know how critical they are to your operation. Slow, poor-quality printing can really cause bottlenecks and impact productivity.  In this blog we discuss how to improve manufacturing efficiency with the Honeywell PD45S industrial barcode printer. From tracking inventory to ensuring smooth production workflows, high-quality barcode labels are vital to all aspects of the workflow. Poor print quality, slow label production, and non-compliance fees due to unreadable barcodes are all too common. The PD45S is specifically designed to tackle these problems head-on, helping you streamline processes and boost productivity.

Barcode Printing Challenges in Manufacturing Environments
Barcode labels play a critical role in daily operations. They ensure accurate inventory tracking, facilitate production workflows, and support compliance with industry regulations. However, older technology, or barcode printers that do not offer the reliability needed in this type of environment, can lead to several challenges:

Unreadable Barcodes: Poor print quality results in unreadable barcodes, leading to scanning errors, production delays, and costly non-compliance fees.

Slow Printing Speed: In high-volume environments, waiting for barcode labels to print can slow down production lines, creating bottlenecks and reducing overall efficiency.

Frequent Downtime: Barcode label printers not designed for rugged environments are prone to maintenance issues and can disrupt workflows and increase costs.

The Honeywell PD45S industrial barcode printer addresses these challenges with advanced features and capabilities designed specifically for manufacturing environments.

Key Benefits of the Honeywell PD45S

1. Superior Print Quality
The PD45S is equipped with a high-precision printhead, ensuring consistent, high-resolution labels that are easy to scan. Advanced thermal transfer and direct thermal printing technologies deliver sharp, durable barcodes, reducing the risk of non-compliance fees caused by unreadable labels.
2. High-Speed Printing
With a print speed of up to 12 inches per second, the PD45S keeps up with the demands of high-volume production lines. Faster printing reduces downtime, ensuring production personnel always have the labels they need when they need them.
3. Durable and Reliable Design
Built with a robust metal frame and industrial-grade components, the PD45S can withstand harsh manufacturing environments. The printer’s reliability minimizes unexpected downtime, helping maintain smooth operations.
4. Flexible Media Handling
The PD45S supports a wide range of label sizes, materials, and formats, making it versatile enough for various manufacturing applications. Easy media loading and adjustments simplify operations for production staff.
5. User-Friendly Features
A large, intuitive touchscreen interface allows for easy setup and operation. Remote management capabilities enable IT teams to monitor and maintain the printer from anywhere, reducing the need for on-site support.
Areas where the Honeywell PD45S Excels
The Honeywell PD45S is an excellent choice for various areas within a production facility. Here are some examples of how this printer can benefit specific departments:

1. Receiving and Inventory Management
Quickly print labels for incoming components to ensure accurate tracking and storage. Improve inventory accuracy and reduce time spent searching for misplaced items with properly labeled items.

2. Production Line Operations
Produce labels for work-in-progress items to streamline assembly and packaging workflows. Eliminate delays caused by slow or unreliable printers, keeping production lines running efficiently.
 
3. Quality Control and Compliance
Generate high-quality labels that meet industry standards and ensure regulatory compliance. Avoid costly penalties or rejected shipments due to unreadable barcodes.

4. Shipping and Logistics
Print shipping labels with quality-printed, readable barcodes to ensure fast and accurate order fulfillment. Reduce errors in shipping processes, and improve overall customer satisfaction.

Why Choose the Honeywell PD45S?
Manufacturing companies that switch to the Honeywell PD45S can expect significant improvements in productivity, accuracy, and overall efficiency. Here’s why this printer is worth considering:

Enhanced Productivity: With its high-speed printing capabilities, the PD45S eliminates delays caused by slow label production.

Cost Savings: Superior print quality reduces the risk of non-compliance fees and prevents wasted materials from reprinting defective labels.

Ease of Use: Intuitive features and remote management capabilities make it simple to integrate the PD45S into existing workflows.

Durability: Built to withstand the demands of industrial environments, this printer ensures long-term reliability and performance.

In our experience, having a device that fits the bill for your application and environment makes all the difference in terms of quality, productivity and reliability.  We have found that the Honeywell PD45S industrial barcode printer is a powerful solution for addressing the common challenges of barcode printing in the manufacturing space (and many other tough environments).  
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If your operations struggle with unreadable barcodes, slow label production, or frequent printer downtime, it’s time to upgrade to the Honeywell PD45S. Contact us today to learn more about how this innovative printer can transform your operations and drive success in your manufacturing processes.