Machine automation: The next big competitive advantage

INNOVATIVE PRODUCTS and processes always start with an idea. One of the most impactful ideas in the history of manufacturing occurred when someone realized that computers and machines could "talk" to each other, thereby opening up a new world of possibilities on the shop floor. Since then, manufacturing has never been the same.

As machines become more automated, many can now make parts without needing an operator to run it. Others can function with only minimal human interaction. In some facilities, entire manufacturing plants are operated by robots. Other plants are gradually updating their machines. The ability to automate select machines and processes opens up new opportunities to get faster, more efficient and more competitive in today’s global manufacturing markets.

For example, CNCs may be loaded to run lights-out after the first shift leaves. This allows the machines to run parts at night without any machinists unloading each job to allow the next to run. This enables plants to increase production and reduce labor costs by running night shifts with minimal staff.

This is just one example of how machine automation and the ability to send labor and material information to the ERP system is radically changing the manufacturing landscape. Let’s look at three ways automation is allowing manufacturers to lower costs and increase speed while still producing high quality parts.

Nesting Software

Nesting software has rapidly become one of the most popular trends in machine automation due to its ability to optimise raw material usage during the cutting process. It is especially useful for metal working, fabrication and job shops that use large pieces of material for some or all of their jobs. Nesting software analyses the parts to be cut and automatically designs the most efficient pattern for cutting the material with the least amount of scrap.

It is a huge advantage if your Nesting software can communicate with your ERP system. As a result, the schedule in the ERP system can be sent to the nesting software and then the labor and material can be sent back to the ERP system. At Global Shop Solutions, our ERP software includes an interface with the capability to automate the router with the Nesting program, thereby eliminating the need for manual data entry. The interface also enables the Nesting software to send all the job information directly to the ERP system, such as labor time, quantity of material pieces used, and the number of usable remnants to be put back in inventory.

Nesting software generates more efficient use of materials and labor, making the manufacturer way more efficient overall. Its ability to cut different parts on the same piece of material reduces material handling transactions. It also supports more accurate estimating and results in less scrap.

Machine Monitoring

Today’s sophisticated production machines produce large amounts of raw data for each job. Increasingly, manufacturers are using machine monitoring systems (MMS) to take advantage of this treasure trove of machine performance information. Using everything from monitoring and analysis software to industrial sensors and touch-screen interfaces, MMS captures the data and translates it into actionable information that can be posted around the shop floor.

Before the development of machine monitoring, gathering, organizing, analysing and disseminating this kind of information required a lot of time and manpower. MMS automatically organises the data in production dashboards that provide a visual representation of key performance indicators (KPIs). When machinists and other workers can see what’s going on in real time it improves throughput and efficiency. 

Machine monitoring creates an objective measure of machine performance, but an MMS does more than just collect data. These systems can automatically alert managers when a particular threshold is crossed, thereby preventing or minimizing machine damage and unexpected downtime. They also provide an accurate record of each machine’s life-cycle, allowing for scheduling of maintenance and repairs based on actual wear and tear rather than guesswork.

Machine monitoring improves inventory usage and resource consumption efficiency by measuring exactly what goes into each machine, what comes out, and the amount of energy required to produce the job. Gone are the days of monitoring setup vs. run and indirect vs. direct. These metrics are still something to watch, but ‘spindle’ time is the key to making parts. MMS software can also share data with ERP systems, providing quick comparisons of estimated versus actual performance and allowing plant managers to monitor job status from anywhere with a smart phone or mobile device.

Ultimately, machine monitoring fosters a shop floor culture driven by precise data  – are we making parts? When managers and machinists consult data at every stage of the manufacturing process, you get faster production, fewer quality issues, and more jobs completed on time. 

Material Handling

Imagine how much time and effort it would save if you could locate, retrieve, move, and store the materials you use to make parts without manual labor. Automated materials handling (AMH) reduces or eliminates the need for workers to check in, check out and sort material or place it on the machine for cutting or production. 

AMH systems use everything from conveyors, box lifts, pallet lifting, and industrial lifting devices to computerized devices and robots to remove the human element from lifting, moving, retrieving and storing materials. Suppose you regularly put sheets of nested material on a laser for cutting. A programmed material handling machine with four suction cups can lift the sheets and lower them into the exact location on the machine without human intervention.

Automating material handling can require a large capital investment as well as skilled operators to program and handle the machines. But the long-term gains in efficiency and productivity far outweigh the costs. The machines move and load materials faster and with greater accuracy, and can be programmed to handle more than one process at a time. AMH also maximises storage space efficiency. For example, automated forks can safely stack materials at high levels without wasting space.

AMH reduces order handling errors and streamlines the shipping process for faster delivery. It also enhances workplace safety by eliminating the need for employees to lift or carry heavy weights, thereby reducing the risk of injury. The big bonus is the ability to feed the machine material lights-out. 

Look Before You Leap

The benefits of machine automation can’t be overstated. However, given the cost and complexity of many systems, it should not be considered a quick fix for inefficient processes. Instead, approach machine automation as you would the acquisition of any long-term asset – from a strategic perspective. 

Identify problems that are currently slowing down production, and select one that can have a significant impact if rectified. Carefully analyse how automation can solve the problem, and identify the expected benefits and return on investment, making sure to align your automation strategy with your business and operations strategies. If you achieve the desired results, move on to the next problem automation can solve.

Despite all that machine automation can do, it’s going to continue getting better. The advancements that will occur in the upcoming years make this an exciting time to be part of the manufacturing industry!

Mike Melzer is vice president operations/service at Global Shop Solutions

For more information: 

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