In the recent manufacturing industry, problems due to soaring labor costs and human troubles are becoming more serious. In this trend, the automation of the production line has become so important that it can be said that it is indispensable. So this time
If you want to learn more, please visit our website high speed integrated production line.
- We are considering automating the production line
- I want to improve production efficiency
- I want to know the case
We will answer your questions.
If you are considering automating your production line, or are curious about the current state of automation, we hope you will find it helpful. Automate your production line
- I want to reduce costs by saving labor and manpower.
- Increase productivity and increase sales
- I want to reduce human error and increase quality value
- I don’t know which manufacturer’s device or robot should be used for efficiency
1. Why more and more companies are automating their production lines
Companies that feel the importance of automating their production lines are already working towards automation.
The importance of automation has been talked about for a long time, but why has it started to attract more attention recently, and more and more companies are introducing it? The reason is
- Soaring labor costs both in Japan and overseas
- chronic labor shortage
- Productivity review
I can give you something like this.
Until now, the flow of manufacturing has maintained productivity by hiring a large number of workers at low wages.
However, recently, labor costs have risen even overseas, and the current situation is that it is no longer possible to use the same production methods as before.
In addition, due to the diversity of work styles, labor shortages are occurring at every factory. It is clear that this trend will continue to grow.
Then, no matter how much you want to produce it at the factory, you will be in a situation where you can’t.
Therefore, the automation of production lines has become a focus of attention.
2. Purpose of automating the production line
Introduce the purpose of automating the production line.
(1) Maximize profits by improving productivity and stabilizing quality
I think the purpose of automating the production line will differ depending on the company.
However, they all have one thing in common: maximizing profits.
By automating the production line, you can expect “improved productivity” and “stability of quality”.
Ultimately, automating production equipment should be considered by any company, as it will ultimately lead to profits.
(2) Eliminate the negative factors of 4M (people, machines, materials, methods)
In production, “productivity” and “quality” are greatly related to the following things called “4M” of manufacturing.
- Man: Worker/human factor
- Machine: Factors related to machinery and equipment
- Material: Factors related to raw materials
- Method: Work method and factors related to method
These 4Ms are a factor in all productivity and troubles related to manufacturing.
Recently, “Media: Causes related to information”, “Management: Causes related to management”, and “Environment: Causes related to environmental changes” have been added to the term “6M1E”, but the above 4Ms are becoming more important.
Above all, “Man: Worker/Human factors” is the most important part of 4M. Because it’s all about other 3M.
By automating the “workers” who are related to all factors to “robots”, in other words, by automating the production line, it will lead to improvements in productivity and quality.
3. Benefits of automating production lines
That said, I think it’s hard to imagine in concrete terms what benefits there are in automating the production line.
So, I will explain the merits of automating the production line.
The advantages of automating the production line are:
- Increased productivity
- Stable quality
- Elimination of unspecified factors
- Reduced labor costs
I can give you something like this.
(1) Improving productivity
Humans cannot work 24 hours a day.
Of course, you can continue to work in shifts, but there are still limits.
Robots can operate 24 hours a day, 365 days a year. In addition, because they can work faster than humans, the number of production increases dramatically.
As an example, there are cases in which equipment that has automated production lines has increased production volume by three times, even though the number of workers has been reduced to one-third.
(2) Stable product quality
Even if it is the same process,
- Worker proficiency
- physical condition of the worker
Due to human factors such as, there will be variations in product quality and production numbers.
With a robot, it is possible to maintain a constant level of quality no matter who operates it.
(3) It is easy to identify the cause, and it is possible to improve smoothly.
Variation occurs due to various factors until the product is completed.
Of course, there are times when defective products are produced due to human error. As human beings, this is inevitable.
At present, it is difficult to deal with or improve these human errors because they are so vague that the work was not accurate due to lack of sleep, or that there was a problem with the production method in the first place.
Automating the production line makes it easier to identify the cause of defective products and troubles. Also, if you look at the data, it will be easier to find problems, so you will be able to improve them immediately.
(4) Leads to reduced labor costs
By automating the production line, labor costs can be greatly reduced.
We can reduce the number of workers required for the entire factory, and it is also possible to reduce the sudden cost of securing the necessary human resources when workers suddenly quit.
4. Example of improvement by introducing automation of the production line
Product Name
Delivery destination
Usage
Realized
Technology used
Auto parts assembly equipment
automotive industry
Labor saving and labor saving
Achieved labor saving by machine. Prevents variations in products that would occur if done manually.
・Z-fold
The workpiece is mountain-folded and valley-folded for storage.
Advanced technology is used to neatly fold one piece of work. ・Automatic elevator
Adjust height. It can be adjusted according to the height of the worker. ・Human-friendly device
Since it is a joint work between the device and the person, it is adjusted so that it does not hurt even if the hand is caught. ・Automatic speed adjustment
Since it is folded while rolling, the warp expands.
If the winding is too fast, the workpiece will tear, and if the winding is too slow,
To prevent this, we adjust the speed at which the robot descends and its rotation speed.
Established coordination between rotation speed and processing speed with PLC. ・Support for various types of jigs
Workpieces can be removed and attached with a single touch.
Product Name
Delivery destination
Usage
Realized
Technology used
Assembling the heads of industrial inkjet printers
OA equipment industry
labor saving
Apply glue automatically using XYZ. As a result, the application position and application amount can be stabilized, saving labor.
・XYZ robot
The application position can be specified as desired. I am doing PLC control. ・Adhesive application system
Quantitative application is realized.
UV and adhesive can be applied with one device. ・Shutter for UV irradiation
If you see it with your eyes, you may lose your eyesight, so we set up a shutter to prevent the UV from leaking outside. ・Clean before applying adhesive
Adhesive may clog the tip of the needle if it is not cleaned. Therefore, it is always cleaned and then applied, achieving a fixed amount of application. ・Installation of area center
Safely designed to stop when a person enters the retracted position
5. Issues and disadvantages of automating production lines
Automating your production line has many benefits. However, automation still has its challenges and disadvantages.
So, let’s consider whether to introduce automation depending on the situation and purpose of your company.
This time, I will introduce the disadvantages and issues that can be considered when introducing automation of the production line.
(1) High introduction cost
The biggest problem in automating the production line is the cost at the time of introduction.
- Training and employment of engineers
- Coordination with related line equipment
- Ensuring safety
In addition to introducing robots, there are other costs involved.
In automating the production line, we have to calculate all the necessary costs.
Having said that, it is a wise choice to have an estimate, as it is not possible to calculate even a rough estimate without first knowing how much it will cost to introduce a robot.
(2) Unmanned operation is difficult
Even if the production line is automated, the current situation is that it is difficult to make it completely unmanned.
Want more information on High Productivity 2 Sides 1 Coating Line? Feel free to contact us.
- Robot adjustment
- Maintenance management
- Human work in detail
It may be difficult to automate the parts that absolutely require workers, such as the above.
However, it is not 100% impossible, so if there is a part you want to automate, it is a good idea to consult with us once.
(3) We need excellent human resources
The introduction of robots will eliminate the need for human resources as workers.
However, after introducing a new robot, we need human resources who can “operate and manage” it.
You can train them in-house, hire them, or outsource them.
No matter what you choose, you’ll need new talent, so keep that in mind.
Most manufacturing facilities are looking to lower the costs associated with their production in order to maximize their profits. Over time, many scheduling techniques have emerged as a way to help these manufacturing facilities meet their production goals and increase their efficiency.
Just-In-Time manufacturing was designed to help manufacturers reduce inventory-related costs by receiving materials and producing goods only when they are needed. Just-In-Time scheduling is used to accommodate last-minute changes to orders and prevent damage or spoilage of inventory by preventing jobs from starting too early.
Just-In-Time (JIT) Manufacturing: Producing What's Needed, When It's Needed
Just-In-Time (JIT) manufacturing is a production strategy that aims to produce goods or services exactly when they are needed, and in the quantities demanded by customers. The primary objective of Just-In-Time (JIT) is to minimize waste, reduce inventory levels, and increase efficiency in the production process.
When the techniques are implemented, production facilities are able to align their raw material orders directly to their production schedules so that these items do not have to be stored for long periods of time. Just-In-Time production scheduling prevents jobs from being scheduled much before they are needed, which requires WIP items to be held in inventory. JIT means that your production operations start with just enough time to be completed by the need date so that your goods are being produced to ship, not to be stored.
There are many benefits associated with Just-In-Time production, but the main goals of this method is to increase the efficiency of production while decreasing waste to ultimately lower the production costs and increase profits. On the flip side, implementing JIT methodology requires producers to be able to accurately forecast their demand to avoid running into material shortages.
Before implementing Just-In-Time strategies, it is essential to understand the advantages and disadvantages of the process.
Advantages of Just-In-Time (JIT) Manufacturing
The advantages of Just-In-Time (JIT) manufacturing include the following:
Reduced Space Needed - With JIT you have a faster turnaround of stock, which means that you do not need a lot of warehouse or storage space to store goods or materials. Ultimately, this will reduce the amount of storage space your organization will need to rent or buy, which will free up funds for other parts of the business.
Smaller Investments - JIT inventory management is an ideal methodology for small production facilities that do not have the funds needed in order to purchase huge amounts of stock at once. Ordering stock materials only when they are needed enables you to maintain a healthy and smooth cash flow.
Waste Elimination/Reduction - A quicker turnaround of stock prevents goods that have become damaged or obsolete while sitting in storage, reducing waste. This again saves money through preventing investment in any unnecessary stock and reducing the need to replace old stock.
While there are many advantages to the Just-In-Time manufacturing methodology, there are also some drawbacks to it as well. Listed below are some of the disadvantages of Just-In-Time (JIT) manufacturing.
Disadvantages of Just-In-Time (JIT) Manufacturing
The disadvantages of Just-in-Time (JIT) Manufacturing include the following:
Risk of Running Out of Stock - With JIT manufacturing, you do not carry as much stock. This is because you base your stock off of demand forecasts, and if those are incorrect, then you will not have the correct amount of stock readily available for your consumers. This is one of the most common issues with manufacturing that utilize methodologies such as JIT and lean.
Dependency on Suppliers - Having to rely on the timelessness of suppliers for each order puts you at risk of delaying your customers’ receipt of goods. If you are unable to meet consumer expectations, then they could take their business elsewhere. This is why it is important to choose reliable suppliers and have a strong relationship with them so that you can make sure that you have the materials you need to meet your customer demands.
More Planning Required - JIT inventory management requires companies to understand sales trends and variances in close detail. Many companies have seasonal sales periods, meaning that a number of products will need a higher stock level to combat consumer demand. Therefore, you must plan ahead for instances like this and ensure that your suppliers are able to fulfill the requirements.
A software that can aid with Just-In-Time (JIT) manufacturing is PlanetTogether’s Advanced Planning and Scheduling software (APS).
PlanetTogether’s APS software will automatically schedule your production operations so that they start with just enough time to be completed by their needed dates. For example, if an operation has a work content of one hour, the Just-In-Time start date will be set to one hour before the operation’s need date.
Release rules can be applied to allow operations to schedule before their JIT start dates. Slack days provide some additional time between the end date of the operation and its need date to accommodate last-minute variations. The flexibility of PlanetTogether APS allows manufacturers to set different scheduling rules on different machines.
APS software has become a must for operations that are seeking to take their production to the next level and can easily aid with efficiency increase, inventory control, waste elimination, and cost reduction. PlanetTogether’s APS software will take your production facility to the next level and turn your shop floor into a goldmine.
The shift to PlanetTogether is saving us about 15% in inventory overhead and about 20% in overtime labor expenses. We're not building equipment to stock any longer - we're building to ship.
BRUCE HAYS, DIRECTOR OF MANUFACTURING, J&J SYNTHES
Advanced Planning and Scheduling (APS) Software
Advanced Planning and Scheduling Softwares have become a must for modern-day manufacturing operations as customer demand for increased product assortment, fast delivery, and downward cost pressures become prevalent. These systems help planners save time while providing greater agility in updating ever-changing priorities, production schedules, and inventory plans. APS Systems can be quickly integrated with an ERP/MRP software to fill the gaps where these systems lack planning and scheduling flexibility, accuracy, and efficiency.
With PlanetTogether APS you can:
Create optimized schedules that balance production efficiency and delivery performance
Maximize throughput on bottleneck resources to increase revenue
Synchronize supply with demand to reduce inventories
Provide company-wide visibility to resource capacity
Enable scenario data-driven decision making
The implementation of an Advanced Planning and Scheduling (APS) Software will take your manufacturing operations to the next level of production efficiency by taking advantage of the operational data you already possess in your ERP system. APS is a step in the right direction of efficiency and lean manufacturing production enhancement. Try out a free trial or demo!
Leading manufacturers choose PlanetTogether's production scheduling software to maximize profitability. Improve lead times, optimize inventory, and gain a competitive edge.
Related Lean Video
Are you interested in learning more about coil coating machinery? Contact us today to secure an expert consultation!
APS Resources
InfographicsCase StudiesWhite Papers