As Industry 4.0 sweeps the manufacturing world, the tangible benefits of increased production and quality of products are visible to many. The introduction of revolutionary manufacturing processes, such as enhanced automation, data exchange and advanced analytics, are refining these processes further, transforming the landscape.
We recognise that the initial investment in an automated system can be significant. However, transitioning to automation offers substantial benefits, including increased productivity, enhanced quality control and reduced costs.
Automation in Manufacturing Increases Productivity
Automation enhances the productivity and efficiency of processes, leading to higher product output and profitability.
A production line solely reliant on human operators is inefficient in today’s consumer-driven world. Product consistency is vital, leaving no room for error. Manual errors can be costly, reducing product quality or increasing product variations. These expensive mistakes negatively impact your company’s finances and reputation.
Additionally, workers tire during busy trade periods, leading to slower production or increased manual labour to aid this rise in demand, increasing expenses.
When considering automation, you must factor in monetary benefits. For example, Reduced lead times constitute a massive improvement, enabling more effective fulfilment of customer demand and a positive brand impact. Reducing human interaction in the production process allows you to extend manufacturing times.
Although automated production lines can have faults leading to downtime, manufacturers schedule “Preventive Maintenance” during these periods. They assess production lines for potential faults and often optimise them to address potential obsolescence. These planned periods allow production lines to work 24/7, increasing product throughput.
Discourse concerning the tangible benefits of automation omits scalability, flexibility, and competitive edge. The manufacturing environment is constantly changing; businesses need to adjust rapidly to stay competitive now and in the future. Automated systems are versatile, quickly re-programmable and reconfigured to enable new product production. As a result, manufacturers can alter production lines to create a product, increasing capabilities for a market advantage.
Regarding competition within the market, automation provides an edge. There is no doubt that now automation is widespread, your competitors will use it within their production lines. To stay competitive, automated cells, bar feeders, and APLs help you decrease cycle times and cost per piece while improving quality. Coupling this with data-driven decision-making will refine processes and predict maintenance requirements and bottlenecks within the production line.
Enhances Quality Control
Consistency and quality of products are the key to keeping existing customers. Matching a consumer’s expectations of a product is vital; meeting their needs to ensure their satisfaction and brand loyalty. Enhancing quality control is a natural way to achieve this.
Automation enables a higher level of quality control. Leveraging machine learning and computer vision within the quality control system will optimise the accuracy and consistency of identifying product defects.
Tracking and tracing the product is another crucial element; knowing exactly where your product is within the production and distribution context. Manufactures utilities information forms the distribution network to understand their consumer better, along with regulatory compliance and industry standards.
Reducing Operating Costs
The return on investment (ROI) from automation manifests through various avenues, including reduced company overheads, lower operating costs, and decreased expenses for manual labour.
Discussions of reducing operating costs bring forth the fear of job redundancy within the manufacturing sector. This fear needs to be demystified. Automation manages repetitive and routine tasks more efficiently than humans, but it complements our abilities, creating new job opportunities that allow workers to focus on more engaging tasks.
Reducing operating costs also improves energy efficiency within production lines. Sustainability is taking centre stage; manufacturers are creating products through economically sound processes, minimising their negative environmental impact.
Meters and Sensors allow manufacturers to monitor energy consumption. The data is invaluable, providing operators insights into reducing energy usage within the production line.
Need a High-Quality Automated System for Your Facility?
Integrating a new automated system into your business can feel daunting; Elmleigh can manage the project from conception to completion.
We specialise in all aspects of industrial automation, offering a turnkey solution, from design and installation to inspection and testing of new systems. We manufacture control panels for automated conveyor systems.
We offer tailored bespoke designs fabricated in-house at our UK facility, installed on-site by our dedicated mechanical and electrical installation teams, complying with industry health and safety regulations.
Contact Elmleigh today to start your automation enquiry! Contact us on 01455 847045 or fill out the form on our contact page, and one of our automation experts will be in touch with you.