Did you know that improving manufacturing efficiency can increase output by up to 30%? Even minor inefficiencies present opportunities for substantial gains. Manufacturing efficiency plays an important role in driving economic growth. It allows producers to offer goods at lower prices, which increases consumer spending.
Employees can enjoy a higher salary as the business is now in a good position. And when more manufacturers follow efficient manufacturing, it contributes greatly to economic growth as well. Furthermore, efficient manufacturing attracts domestic and foreign investments. This increases the country’s industrial base.
By focusing on the seven key areas discussed below, you can streamline your processes and achieve good manufacturing results. From what defines manufacturing efficiency to how to improve manufacturing efficiency to manufacturing process improvement examples, and more, this blog provides practical and actionable strategies to help you improve your manufacturing operations effectively.
What is Manufacturing Efficiency and Why it Matters
Manufacturing efficiency is about producing high-quality items using minimal resources. It entails modifying a few or more aspects of the manufacturing process to reduce waste, cut expenses, and enhance manufacturing productivity.
Efficient manufacturing improves production profits, quality, and satisfaction among consumers. To gain a competitive advantage in the market, you must demonstrate a good understanding of manufacturing efficiency.
Additionally, employees benefit from the increase in manufacturing productivity by reducing repetitive tasks that cause fatigue and errors. It improves workplace satisfaction and the physical well-being of the employees by reducing organizing workflows.
7 Ways to Improve Manufacturing Efficiency
The question arises: “How to improve manufacturing efficiency?”. Here are seven actionable manufacturing process improvement ideas:
1. Automate Tasks
Automation is the key to modern manufacturing. In labor-intensive activities, automation drastically reduces errors and significantly increases productivity. By implementing automation, you can redirect your workforce to higher-value assignments, optimizing both human and machine resources for maximum efficiency.
Robots are integral in achieving this. They simplify things while improving accuracy and quality. The use of robots also improves safety for potentially dangerous activities like welding, handling hazardous materials, operating heavy machinery, and more.
For example, using robotic arms for arc and laser welding might be achieved within a shorter time than traditional approaches. These robots ensure that every weld is done properly and reduce the need for weld redos to increase the quality of the products. Such automated systems can also generate real-time data on different performances and identify areas requiring attention.
2. Optimize Workflows
Workflow management is streamlining the movement of material, information, and resources throughout the manufacturing chain. As a result, it is possible to cut unnecessary time figuring out specific parts of the process. Tools like value stream mapping and Six Sigma can help with this.
For instance, introducing Six Sigma into your painting process gives you access to workflow data and lets you analyze the process. You can then determine which steps can be deleted or optimized. This in turn results in increased production efficiency.
3. Implement Lean Manufacturing Techniques
Another manufacturing process improvement idea is lean manufacturing which can eliminate any type of wastage while maintaining efficiency in the process. This approach follows regular inspection of the production system for further enhancements. Techniques like JIT (Just-In-Time) production, Kanban, and 5S (Sort, Set in order, Shine, Standardize, Sustain), and more can help make your production unit obey superior standards.
Let’s say we bring in the JIT production in a welding process. When this is in place, the material will only be sourced when required. This synchronizes material supply with production schedules and streamlines workflows, eventually resulting in reduced waste. The 5S methodology helps maintain a clutter-free workplace. When employees spend less time searching for tools and other items, productivity significantly increases.
4. Enhance Employee Training
Your employees are the nerves of your production efficiency. Providing them with frequent and extensive training is crucial to address contemporary technologies and procedures. The training should include those concerning lean manufacturing and efficiency enhancement of the flow.
Training programs for employees should also be seen as an investment that can bring a lot of benefits in the future. Trained employees provide better results, and are better prepared to face new challenges and technologies.
5. Maintain Equipment Regularly
To avoid equipment failures and production stoppages, equipment must be well maintained. Follow habits like timely inspection, repair, and replacement of wearing-out machinery. Organizations using predictive maintenance technologies can mitigate failures and plan for them in advance. This way, the time wasted is minimal.
6. Leverage Real-Time Data
One of the benefits of using real-time data in manufacturing processes is that it enables you to make the right decisions quickly. Use sensors and IoT devices to collect data on machine efficiency and quality. Studying these numbers enables you to identify patterns and challenges in the workflow that can be fixed timely.
For example, real-time data on welding machine performance can reveal temperature fluctuations or inconsistencies. Monitoring these metrics can help you make immediate adjustments to maintain optimal performance and standards. This real-time data can also be used to monitor key performance indicators (KPIs) such as overall equipment efficiency (OEE) and first pass yield (FPY).
7. Energy Efficiency
Energy efficiency is one of the most ignored areas regarding manufacturing efficiency. Perform energy audits from time to time. This helps you evaluate the overall energy consumption and identify areas of wastage in your facility.
Upgrade the appliances to new ones as modern equipment uses less power and can work faster. Efficiently maintain and operate your heating, ventilating, and air conditioning systems. Consider routine servicing, replacement with more efficient devices, and using automatic thermostats. Raise awareness of energy efficiency among the employees and train them to operate in ways that save energy.
How Augmentus Improves Manufacturing Efficiency
So how to improve manufacturing efficiency? Augmentus robot software solutions drive your manufacturing efficiency forward. Our primary functions are to ease robotic programming, boost flexibility, and guarantee constant production. Here are some manufacturing process improvement examples by Augmentus:
Comprehensive Robotics Solutions
Augmentus offers “Scan to Path” technology. In operations like painting, you can automatically turn the 3D scans into accurate (up to 0.1mm) robot paths without coding. This cuts down the time required for robotic programming configuration. Without needing robot engineers, you can deploy robots 5 times faster than usual.
Seamless Integration and Compatibility
Augmentus also integrates with a vast range of industrial robots and tools. By integrating with multiple robot brands, you can modernize while keeping your existing systems in place. This avoids heavy new investments and facilitates the transition to a more efficient manufacturing process.
Intuitive Interface
The platform offers a working interface that lets you effectively design and reconfigure workflows. The average time taken to build a master program on Augmentus is as low as just 14 minutes. Even if you are someone with minimal programming knowledge, you can make the most out of your robots with Augmentus.
Conclusion
Fine-tuning the manufacturing process is almost always a work in progress. While more and more technologies are developed, one should be informed and adaptive to have an upper hand. The tips discussed in this blog are sure to help you see changes in your overall manufacturing efficiency. If you are interested in automating your manufacturing unit, speak with an automation expert today.