Staying competitive in a global economy demands consistent efforts to improve manufacturing productivity. In order to succeed with the objective of sustainable growth and the capacity to generate useful output, manufacturers have to make critical decisions regarding the deployment of resources, implementation of new technologies, elimination of operational inefficiencies, etc. A sound manufacturing strategy plays an integral role in shaping the competitive position of a company.
The more effective your manufacturing productivity, the more profit your company can make. In some cases, it is easy to identify variables that interfere with operational efficiency and productivity. However, it is not always simple to understand the complexity of a process. Once you are determined to improve manufacturing productivity, you will be able to better understand underlying problems and resolve them. Following are simple steps and strategies that can help you improve the productivity of your production plant:
Collect data regularly
As you put efforts to comprehend your manufacturing processes in depth, you become better positioned to enhance your production process. First and the most important thing is to understand manufacturing patterns through data. The number of production hours, efficiency of production machines, time to manufacture each item, output per hour, and productivity of employees are some of the variables that highlight the overall efficiency of a manufacturing plant. Successful manufacturers keep track of everything happening on their factory floors.
It is very important to locate points in your workflow where production gets backed up because production processes are not properly integrated. Integration of production processes plays a vital role in bringing about an efficient factory floor where everything is connected and works in harmony. So, identify and eliminate bottlenecks in order to develop a more streamlined and organized workflow.
Upgrade manufacturing systems
Old-fashioned, manual production processes cannot meet the growing market expectations. Customers demand high-quality products. It will be extremely difficult for a manufacturer to address emerging market trends without implementing innovation and bringing in modern automation technologies. As a manufacturer, you should continuously look for modern production means that are fast, efficient, and flexible. It is the only way to maintain manufacturing productivity over a long period of time.
Industrial automation solution providers offer a variety of affordable manufacturing systems that you can integrate into your existing setup and witness dramatic improvements. Consult a reputable automation engineering company that can develop custom machines and control systems for your factory floor.
Injection molding is a technique used to manufacture parts of a product or whole product by fabricating the plastic. The process in simple terms can be laid down as a process where the molten form of a metal or plastic raw material gets injected into a mold and when solidified is taken out of it to produce a product of the same specifications as the mold. But everything is not that simple as it looks. Someone who wants to take up injection molding as a business needs to understand the whole process in great detail. Let us discuss what the process of injection molding is all about. The process is not only quick and efficient, but cost effective too.
Closing the Mold: The first step of the process is closing the mold. Also known as clamping, the closing of the mold leads to tight grip of the plates over the structure of the mold so that the parts are stuck together with great connection. If not connected properly, the molten plastic material can run through the spaces left and this could lead to deformity of the product manufactured. Wastage of raw material will also be there then.
Injection of the Plastic: Now comes the part of the insertion of the molten plastic material into the already assembled mold. The plastic which is melted from the pellet mold form is then injected with pressure into the mold so that it takes proper shape and no bubbles are formed in the product. The standardized product making is the motto of every company and customers also buy products which offer quality.
Holding of the mold: the next step in the process is holding the mold properly in the right position so that the plastic takes proper form. Once the injection step is done, the mold undergoes pressure just to ensure that all the parts are filled properly. This is known as dwelling. After the dwelling is done, the mold is then set out to cool down so that the parts start becoming solid and can be taken out once fully solidified.
The final stage of ejection: after a standard period of time, the moving platen is given command to move away from the fixed part and this opens the mold. The mold once opened is separated from the product by tapping of a rod or air blast. The product then is ready and can be sent for further making of the product or packaging if ready.
The process of plastic injection molding is too simple to understand, but while executing, the tips included in the above article must be adhered to. Problems while designing or giving commands during manufacturing can lead to a number of problems which could mean inefficiency. This must not be allowed to walk in and the individuals who are responsible for production at site must be trained well as the process is the heart of the company. Only when the product manufactured is of a superior quality can the customers be convinced to purchase it. Quality matters and so does the processing!
Manufacturers are always looking for techniques to reduce their cost. Here are five of them that will help the manufacturers reduce cost irrespective of their sector. The primary step would be to assess their process and do on internal audit. Only when the big picture is at view, methods can be implemented to reduce the costs.
Most of the time without our notice we tend to waste a lot of electricity. Implementing sensors that would stop the machines immediately after usage can reduce quite a lot of cost. Replacing energy guzzling machinery with those consuming less energy can save up to 10% of the cost. Usage of alternative energy sources like solar energy which is the cheapest source of energy can cut down operating cost significantly.
Fixed Cost Reduction
Machinery for a manufacturing industry is very important, but only a few machineries are constantly used. Hence, owning the machinery that is used passively wouldn’t be feasible; renting/leasing such machinery can reduce the fixed cost. Using automation in production process can decrease the labour cost abundantly. Outsourcing advertising, marketing and sales could also help in cost reduction.
Overhead Cost Reduction
Maintaining inventory by not over producing and recycling/selling the wastage or scrap of the raw material can always free up and manage the factory space and reduce wastage. At times, outsourcing supply can reduce the business space, risk, staff, and maintenance of vehicles. Buying raw materials at bulk and sharing it with another manufacturer can reduce the material and inventory space. Intercom and internet calling, conferencing and video calling meetings can help reduce administrative cost.
Reduction in Labour Costs
Usage of technology for the manufacturing process like implementing sensors and automation, robotics can drop down as the number of labours drops as the automation requires less human interference and is more accurate. Using part time workers and free lancers can eliminate the idle time of labourers. Implementing methods to increase efficiency; comfortable positive workplace, eliminating overtime as it reduces efficiency, training employees, getting to know the employees, reskilling of the employees rather than assigning them monotonous task can help the manufacturer make optimum use of the labour force.
Customer related cost reduction
Technology can help the manufacturer cut down the cost in every stage of the manufacturing process and also at marketing. Using technology for marketing, advertising and promoting of goods can reduce cost abundantly. Designing products digitally 3D print of the product would help the manufacturer in better understanding of customer needs and can reduce correction and reproduction.
An electric generator gives electrical power when there is inadequate or no accessible power supply, guaranteeing that regular exercises and business activities keep amid a power blackout. Besides giving a crisis reinforcement control supply, a generator can likewise be utilized to give consistent energy to inhabitants and organizations in remote areas that are not come to by mains electrical administrations.
There is an extensive variety of fresh new and used generators accessible with various particulars and in different sizes. We give a few hints on the best way to purchase the best generator for your prerequisites.
Recognize your Prerequisites
What will you utilize the generator for? It is safe to say that you will utilize it to control overwhelming machines or will you utilize it for power backup for your home or business? For home or individual applications, a solitary stage control generator with 5kW to 30kW will do the trick. For modern applications or to control a vast business, three stage control generators from 30 kW to 6 megawatts are suggested.
Some outstanding brands offer an extensive scope of generator sets. To figure out which one fits your prerequisites, do some exploration. Look the Internet for more data about each brand. Prevalent brands will in all probability have their own sites or providers of these brands may have their accessible generators recorded on the web. You can likewise look at item posting sites or discussions and see what different clients have said with respect to a specific generator display. Doing some exploration can give you a superior thought of a generator’s detail and value goes.
Chat with a Specialist
If you require help in obtaining a generator, it is best to discuss your necessities and worries with a put stock in mechanical gear and generator provider. They can talk about with you in detail the pros and cons of purchasing generator and guide you through the way toward purchasing the most fitting generator that fits your determinations. They can guide you on warranty that may not be cost effective for your intended purpose or budget. Some new generator models may expect purchasers to hold up before they can get the unit in view of constrained accessibility.
On the off chance that there is ever an end situation that happens, having a generator will be of great significance. A generator will give power to you and your home for the numerous things we require.
CNC machining is a popular type of tool used in many industries, including manufacturing. It is very effective at speeding up the manufacturing process because it is a highly automated machine. Alternative tools like the manual shaping machines, center lathes and vertical millers are entirely operated by the trained engineer, but this human input is mostly removed when CNC machining is used.
Let’s take a look at a few of the most beneficial reasons to use this manufacturing concept:
High production quality
The use of CNC machining requires a lot less skill and experience to operate compared to most of the conventional tools. Also, with limited human input, there is less risk of mistakes taking place which is certain to help increase the all-round production quality.
CNC machining is a very appealing option when looking to produce a high volume of parts. Once the tool is programmed with precise data, such as the volume and dimensions, it is extremely efficient at replicating thousands of parts one after the other. They are much more efficient than the conventional tools, which are a more practical option for creating the single custom order piece.
The process of operating the CNC machinery is a lot more straightforward than the conventional alternatives. Most tools that need a lot of human input require an operator that is highly skilled and experienced. In a high production factory, this is certain to have a major impact on production costs. However, the highly automated nature of the CNC machinery means there is less need to employ a full workforce. It is more a case of making sure there are enough operators to oversee and input the necessary data.
The software installed in this machinery makes it possible to create pieces with very complex designs that would be difficult to achieve by hand. Also, the software can be updated at a later date to increase the tools functionality. This is certain to help minimize the need to invest in new hardware because the software can be changed or updated when working on different projects.
The CNC machinery gives the option to simulate a design idea without needing to physically cut it out. The ability to avoid making a prototype is certain to help save time and money. If the prototype has a complex design, this has the potential to literally save months of time that could be put to better use.
A company has a great product in mind and has probably designed a prototype. However, if producing it in bulk is too complicated and costly, it is probably about time to work with a manufacturer.
It can be a daunting task to choose the right manufacturer. Most of the manufacturers will probably turn down a company whose production requirements are not big enough to bother with. On the other hand, others may not provide the quality that a company needs. The following are tips on how to choose the best manufacturer to work with.
Search for manufacturers that is ideal for the company.
As a start, the company should decide on whether they want to work with a US-based manufacturer or outsource the job overseas like in China or other countries. Both have their advantages and disadvantages. In general, products made in the US have better quality, making them sell better to discerning customers, while products made overseas cost cheaper when it comes to labor and parts, though shipping fees can add up. The target audience should also be considered in determining whether quality or price is given more priority. Once a decision has been made, the company can go over the website of the manufacturer to know more about their criteria and qualifications. When it comes to overseas manufacturers, a company can visit an international sourcing site. They can check the references and images of products made by the manufacturer. This way, they can determine if the quality of the supplier meets their standards.
If a company wants a manufacturer to take them seriously, they should do extensive research prior to meeting with them. It would be best to create their own prototype or hire someone to do it, but if it is quite complicated, they could ask the help of a product engineer, and ask whether the product can be mass-produced before making the prototype. They should have an estimated budget plus a business plan, which includes the product goals and manufacturing requirements. They should keep in mind that the company is not just deciding on a manufacturer, but the latter is also deciding on the company. When the manufacturer thinks that the company’s idea is not feasible, there will be no meeting in the first place.
Inspect the facility
Prior to making a commitment or signing a contract with the manufacturer, the company should inspect their facility to check out their factory and showroom. This way, they can have an idea of the supplier’s capabilities, plus how well they understand the company’s product and needs. Before making a final decision, the company should visit a number of manufacturers. Since the quality of the product will ultimately depend on the chosen manufacturer, the company will want to make sure that this supplier can be trusted.