Mitigate costs through effective use of technology

The MACH 2022 exhibition, which was organised by the Manufacturing Technologies Association (MTA), took place against the backdrop of a unique set of circumstances, all of them challenging to manufacturers. The lingering effects of the pandemic, ongoing supply chain disruption, mounting cost pressures and international conflicts have all impacted the manufacturing industry to one degree or another. No surprise then that ways of offsetting mounting cost pressures, particularly energy costs, occupied the thoughts of virtually every exhibitor – and visitor – at the five-day show.

Investing in the latest machinery available has the benefit of maximising efficiency by improving productivity and restricting downtime. Such benefits will be felt on a business’s bottom line and softens the return-on-investment equation. 

However, the new machines option is not one available to all businesses, especially in the current climate. Therefore, maximising the benefits of the machines that you do have available becomes the desired goal. Under such circumstances, prolonging the life of machinery will be beneficial in helping to mitigate costs and sustain productivity. In this scenario, accurate and effective maintenance cycles grow in importance.

The increasing use of digitalisation and its associated technology continues to have a revolutionary effect on the manufacturing industry, characterising the way many modern businesses operate. The data generated by machine learning is having a hugely beneficial effect on the ability to accurately interpret maintenance cycles. Being able to predict when maintenance is required rather than having to react to breakdowns is maintaining the productivity of many businesses at a time when surety is most needed.

Planning ahead 

Effective planning of a machine shop prior to equipment being installed will also be beneficial to a business in the long run. Taking time to assess how work flow will be implemented to best effect will help to optimise performance. Also, establishing where raw materials are being introduced into the production process will help to improve efficiency, as will determining where the finished products will end up. 

The shortest distance between two points is always a straight line so making work flows as linear as possible will help speed up the production process, helping cost effectiveness. 

Identifying which processes can be automated and which cannot, will also help. Automation decreases the number of workers on the shopfloor, in turn freeing them up for upskilling and optimising manpower.

Full connectivity should always be available. Digital manufacturing technologies rely on connected systems and processes. This helps create an integrated manufacturing operation, incorporating everything from design to production, as well as predictive maintenance scheduling. 

Temperature control is an essential part of any production operation, therefore effective heating and cooling systems must be in place to ensure optimal production efficiency can be maintained. Businesses need to consider what sustainable solutions might be available as these could be more cost efficient. 

The best location for power and data points should also be determined prior to machine installation. Positioning the points where they can be easily compatible with ancillary equipment such as compressed air is a good rule to follow.

Investing the time to identify the right location will ensure that equipment can easily be added at a later stage should this prove necessary. Having to relocate power and data points at a later stage is likely to incur an additional cost for a business, an outlay that can be avoided providing an effective plan is in place prior to the start of production.

Where possible, the expected lift cycle of the product being manufactured should also be determined. Retooling costs can then be factored into work cycles. Data extracted from the connected systems will be useful here, enabling revisions to design specifications and, future maintenance cycles.

Creating a digital twin of the production operation based on current or expected workflows will help to identify how best to maximise production efficiency. Any approach must be flexible so that changes can be implemented without disruption to work cycles.

Effective modelling and process simulations will improve the quality of production process. Big Data is useful in helping to improve decision making, while generating cost savings, reducing the time a product takes to reach market and creating an efficient, connected process capable of anticipating a range of variables, especially when it comes to maintenance cycles.

Utilising new technologies

There are many more tools available to manufacturers than there were in the search for the most sustainable and cost-efficient production operation. The emergence of new technologies is increasingly steering the future direction of manufacturing. Robotics, 3D Printing and Additive Manufacturing, the Internet of Things, Cloud Computing, Big Data, Augmented Reality, Artificial Intelligence and Cybersecurity are all important aspects of Advanced Manufacturing and key to optimising modern manufacturing processes.

The MTA is keen to further the use of these new technologies and in the case of Additive Manufacturing has taken major strides to advocate the use of the methodology by bringing the only trade association dedicated to the technology under its wing.

AM-UK is specifically designed for companies who work with Additive and 3D printing technology – such as materials suppliers, design services, machine suppliers or post processing services. The association is actively promoting the transformational technologies that are increasingly having a disruptive impact on traditional methods of production, enabling businesses to develop new and better products at lower cost and with greater sustainability. 

At the recent MACH 2022 exhibition, the 3D Printing & Additive Manufacturing Zone was sponsored by AM-UK, helping to identify the products and services characterising the technology. 

Quality checks are key 

It is no coincidence that the most efficient production operations will also be the ones producing the least amount of scrappage. Therefore, quality checks should form an important part of any modern production system. One of the best ways of achieving this is to factor in computer process control through effective metrology.

The key question to remember is 'What is the best way to accurately check that all processes are under constant control?' Whatever the product being manufactured, assessing the number of cycle times required to ensure the business remains viable will be critical. Creating the lowest lead time output will maximise the efficiency of the production process, optimise maintenance schedules and help rein in costs.

Assessing what equipment will be needed to maintain optimum productivity is also critical. For example, determining in advance whether consumable or non-consumable tooling applications are required will improve efficiency and save money on the purchase of unnecessary equipment.

Finally, the human element to any successful production operation should not be overlooked and maximising a workforce’s potential will yield strong results. Continuing Professional Development (CPD) is critical in ensuring skills are up to date and consistent with the needs of a sustainable business. Where upskilling is deemed necessary, this must be implemented due to the requirement to constantly improve technology utilisation