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Lean Manufacturing Assembly

Power Distribution Strategy Is Important for Smart Manufacturing

By Jennifer Pierce
January 9, 2026

As manufacturers push to digitize operations, reduce emissions, and become more flexible, one critical piece of infrastructure is often overlooked: electrical power distribution.

We’re joined by Adrian Sanchez, director of commercial and industrial sales at Starline Holdings LLC, to explore why flexible power distribution is no longer just a technical decision, but a strategic one. From robotics and AI-driven production to rapid facility reconfiguration, Sanchez explains how outdated power systems can quietly undermine innovation, increase downtime, and slow time-to-market.

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Q: How can flexible power distribution be a strategic enabler of resilience, innovation, and sustainability? 

Sanchez: Look at how much we have advanced in manufacturing: robots, cobots, data centers, AI hubs, etc. Every day, we’re finding ways to manufacture faster and more efficiently. But one part we are missing is electrical power distribution. Electrical power distribution can undermine those strategies. And that conversation takes place at a tactical level, but sometimes not at the strategic level. 

I’ll give you an example. Formula 1 race cars use different types of tires that change depending on pavement conditions, weather and race location. The right tire is a critical factor in winning the race.

It’s the same thing with electrical distribution. How are you going to distribute power? How are you going to make your facility adjustable? How are you going to make your facility futureproof? Those are very important conversations. And they need to take place at the strategic level, not at the tactical level, not at hindsight.

 

Q: Why is it essential that we talk about electrical power distribution today?

Sanchez: I’ll give another example. When I checked into my hotel here in Rosemont, and I walked into the room, I never thought that the lights were not going to turn on. I never thought the water faucet wouldn’t open. We go through our everyday lives, and we get busy with work. We get busy with business. And we don’t think about these things; we get so caught up in paradigms and old habits to break.

The electrical power distribution is one of them. It is ironic that we have all these innovations, all these new products and solutions that are so state-of-the-art, yet we are still using electrical power distribution methods that were created 120 years ago.

Looking for quick answers on assembly and manufacturing topics? Try Ask ASM, our new smart AI search tool. Ask ASM →

Let’s think about the traditional methods of pipe and wire. There’s nothing wrong with them, but they were invented about 120 years ago. And that is our status quo. It’s no different than what we do in our house. But in manufacturing, we have other needs that we have to respond to. We have to go to market faster. We have to respond rapidly to change. Let’s think outside the box. Change is constant.

 

Q: What are the consequences of not having the appropriate power distribution system in your manufacturing facility?

Sanchez: If you have to make a change to your power system, it’s going to take you longer. We constantly hear from customers that it takes their maintenance personnel one to three weeks to bring the power exactly where it’s needed. With a flexible power distribution system, you can implement those changes more quickly and minimize downtime. 

People sometimes question the price of busway systems, but they don’t see the real cost. If you have a flexible power system, and you can make change in minutes as opposed to hours or days. That’s going to save you millions of dollars in downtime.

 

Q: What is a Starline track busway? 

Sanchez: The Starline track busway is a flexible power distribution system. It’s a modular, plug-and-play, customizable, scalable system. It’s a great alternative to power distribution that addresses all the situations and concerns I mentioned a few minutes ago.


Q: What are the benefits of a track busway system?

Sanchez: I’m going to give another analogy. When was the last time you were in an airport and had to plug in your cell phone? You have to find the power outlet to plug in your charger. You have to go to where the power is. That power will change the facility’s layout.

Technology is going to change. Everything is going to be rearranged. You have to bring the power where you need it. And sometimes that power could be just a few feet away. If you don’t have a flexible system like Starline, you’ll need to bring an extension cord, or you have to bring an electrical contractor.

That’s going to take time and money. Starline systems are easy to install, move in seconds, and provide power at the point of use. These systems are safe. They have been tested to the utmost. 

For more information, click https://starlinepower.com.

KEYWORDS: assembly line design busway systems flexible assembly power distribution

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Jennifer pierce

Jennifer Pierce was previously a multimedia editor for ASSEMBLY Magazine.

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