4 Strategies to Make Your Production More Efficient in 2021

JERRY PEREZ | July 13, 2021
The start of the new year is a great time to critically take a look at your processes and see how you can improve. Here at FANUC, we have identified four key strategies manufacturers can use to boost their efficiency!

Add Automation
Automation can increase production and efficiency no matter the type or complexity of the manufactured products.  With space at a premium in most production facilities, many job shops look for machine tending robots that are easy to integrate and have a small footprint. FANUC's robots and software make it easy to connect the equipment and improve throughput as well as overall equipment effectiveness. Quick and Simple Startup of Robotization (QSSR) allows up to four machine tools to be connected with a robot using just one Ethernet cable.

Use the Latest and Greatest Machining Practices and Technology
Many manufacturers leave performance on the table due to outdated processes and programming. Are you getting the most out of your machining? Now’s the time to look at the advantages in new CNC technology. Because new controls have greater processing speed and can implement advanced algorithms, they can do a lot more for your operations. Moreover, the interfaces have become simpler and more intuitive, so they are easier to use than ever before.

Digitize Your Process
New digital tools are breathing innovation and life into increasingly more areas of manufacturing, including the application of digital twins in the machining industry. Digital twins provide virtualization of the machine, control and manufacturing process.  Digitalizing traditional manufacturing processes have the potential to make operations more efficient by proving out production processes in the virtual world. That means less waste, more efficiency and a more equipped workforce.

Upgrade Your Shop with a CNC Retrofit
Do you have legacy equipment? Running older machinery can have hidden costs, such as taking the time to source and find older replacement controls leading to significantly longer total downtime and production losses. However, scrapping old equipment and starting new, might be too expensive, especially when factoring in tooling, fixturing, rigging and foundation. Plus, new machines may require more training for staff. A CNC retrofit, with new FANUC CNCs, industrial PCs, servos and cabling, can speed up processing and reduce cycle time by as much as 50 percent.

Spotlight

Bayco Products, Inc.

For 30 years, Bayco Products’ vast array of portable & corded lighting products, have been the preferred choice of professionals and discriminating consumers. The Nightstick and Bayco brands are recognized world-wide as high-performance, high-quality, high-value lighting solutions across virtually every industry.

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How Manufacturing Industry Uses Cloud Technology: Three Case Studies

Article | February 22, 2022

The integration of cutting-edge technologies into the manufacturing industry has transformed the whole economy and accelerated the pace of all operations. Cloud computing for manufacturing is a type of technology that enables businesses to gain visibility, scalability, mobility, security, and improved collaboration, among other benefits. Seeing the benefits, many small and large players in the manufacturing business have embraced cloud computing. “Cloud computing is not only the future of computing, but the present and the entire past of computing.” – Larry Ellison, co-founder, executive chairman, CTO, and former CEO of Oracle Corporation. According to IDC research, the manufacturing industry is the biggest player in cloud computing solutions, with an estimated spending of $19 billion. Additionally, Market Research Future projects that the cloud manufacturing market will reach a value of USD 121.72 billion by 2026. As a result, we may predict that manufacturing cloud computing has a long way to go in the industry. In this article, we will look at some of the key cloud manufacturing applications and case studies of three US-based manufacturing businesses that used manufacturing cloud software ERP. Applications for Manufacturing Cloud Computing Effective Marketing Cloud technology's comprehensive nature makes it an ideal solution for the challenges of marketing campaigns. Manufacturers leverage cloud-based applications to help them plan, execute, and manage marketing initiatives. Manufacturers can also look at production and sales data to see how well their campaign is working. Product Planning and Development Product planning and development are closely linked in manufacturing. Manufacturers can get their businesses ready for full production by integrating product planning and development information with supply chain data and communications. Comprehensive integration enables products to move a lot faster from notion to engineering, from prototype to small-scale production, and eventually to full-scale production and shipping. Production and Stock Tracking Once production begins, cloud technology may assist in the manufacturing and stock management of products. Businesses can use enterprise resource planning (ERP) software to match production levels to available inventory and sales. Pricing quotations, order intake, and client requests can all be managed using the ERP software. Using a standard product to keep an eye on these things reduces the time it takes to get an order. Productivity Management Manufacturers rarely maintain the same level of production throughout the year for all products. They can use cloud-based tools to keep track of when to modify production to meet changing market demands. These software solutions ensure that manufacturers have the necessary raw materials on hand by making communication easier across the supply chain. This helps them easily adjust their orders to accommodate future productivity levels. Three Case Studies of Cloud Computing in Manufacturing Ralco Industries Leveraged Cloud to Cut Its Inventory by 15% Ralco Industries is a producer and supplier of automotive components that specializes in precision-welded assembly and prototypes. To overcome the challenges of their business growth, the industrialists moved to manufacturing software cloud ERP and saved some money in the process. There was a lot of inefficiency, quality issues, excessive expediting prices, and wasted time due to inaccurate inventory and many unconnected systems in the past. Moving to a single integrated cloud ERP software system helped Ralco cut inventory on hand by 15%, scrap by more than 60%. It helped Ralco save money on premium freight by more than 20% and save almost $100 on each purchase order that was processed. Avon Gear Improved Inventory Accuracy and Grew by 20% Yearly Avon Gear Company, a maker of precision-machined components and subassemblies for heavy industrial equipment, was looking for an ERP system that would integrate data across the organization. The company chose a cloud-based manufacturing ERP to manage and record production activity, inventory status changes, receiving, shipping, and other plant-floor data. Consequently, Avon Gear's inventory accuracy has increased, and the company's growth rate has gone up by an average of 20% each year. Wolverine Improved First-pass Quality by 15-20% Using Cloud An automobile brake system technology firm, Wolverine Advanced Materials, found that its manual methods were not sustainable, especially when it came to supporting fast development. To grow and embrace lean manufacturing, the firm chose cloud ERP, which enabled it to properly assess cost and profitability by part. Using manufacturing cloud software, ERP, the company's factory floor workers can see all client orders and conveniently categorize them by material so that they can better manage their schedules. This has resulted in increased production and cost savings for Wolverine. Also, overtime was cut by 60%, while first-pass quality increased by 15% to 20%. Final Word For manufacturers, cloud computing is a game changer. Manufacturing companies must deal with a lot of different sites and supply chains, which requires the use of large, complex database applications. The Cloud computing for manufacturing is expediting industrial operations and overall business decisions in the manufacturing industry. Cloud computing enables industrial organizations to improve visibility across large fleets of facilities. It also contributes to standardization by synchronizing and supplying data for new forms of analytics. Supply chain management becomes more effective and product development gets easier with cloud computing. So, instead of debating whether to use cloud computing, take action and use cloud computing in your business. FAQ What is cloud computing in manufacturing industry? Cloud computing refers to the on-demand provision of IT resources over the internet. Instead of buying, running, and maintaining physical data centers and servers, you can use a cloud service. This approach would help you get computing power, storage, and databases when you need them, rather than buying and running your own. How does cloud computing help the manufacturing industry? Cloud-based solutions are more rapidly deployed than traditional systems, which enables firms to stay current with new innovations. Also, they are easier to change and grow, and they have the potential to make resellers more likely to use them. Why cloud computing vital to modern manufacturing? Cloud computing impacts all aspects of manufacturing. It enables manufacturers to see and control all manufacturing data and take informed production decisions. This is the reason why it is vital to modern manufacturing.

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Rex Moore Proves Project Business Automation Provides Predictive and Proactive Resource Requirements

Article | July 28, 2021

Rex Moore Group, Inc. is a Top50 electrical contractor delivering unmatched integrated electrical solutions. As an early adopter of Lean manufacturing principles, Rex Moore has created a company-wide culture of continuous improvement that drives significant value to their clients. The firm contracts and performs both design/build and bid work for all electrical, telecommunications, and integrated systems market segments. Rex Moore has a full-service maintenance department to cover emergency and routine requirements for all facilities, whether an existing facility or one that has been recently completed by the company. The ability to negotiate and competitively bid various forms of contracts including lump-sum, fixed fee, hourly rate, and cost-plus work as a prime contractor, subcontractor, or joint venture is enhanced with Project Business Automation (PBA) from Adeaca. This solution permits the company to propose work only if they are in a position to be competitive in the marketplace and provide excellent service with fair compensation. Rex Moore used Adeaca PBA as a construction management software for builders and contractors to integrate and facilitate its business processes in its ERP system. Together with Microsoft Dynamics, PBA integrated processes across the company on a single end-to-end platform. This allowed the company to replace 15 different applications with a single comprehensive system, eliminating the costs and inefficiencies associated with multiple systems and silos of information.

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Which Additive Manufacturing Process Is Right for You?

Article | December 6, 2021

Additive Manufacturing (AM) uses computer-aided design (CAD) or 3D object scanners to create accurate geometric features. In contrast to traditional manufacturing, which frequently involves milling or other processes to eliminate superfluous material, these are produced layer by layer, as with a 3D printing process. The global additive manufacturing market is expected to grow at a 14.42 percent annual rate from USD 9.52 billion in 2020 to USD 27.91 billion in 2028, according to reports and data. Overall, the worldwide 3D printing industry is gaining traction due to various reasons, some of which are listed below. Significantly, greater resolution Reduced manufacturing costs as a result of recent technology breakthroughs Ease of creating customised goods Increasing possibilities for printing with diverse materials Funding by the government for 3D printing ventures Additive manufacturing is available or may be implemented in various procedures, which is the primary objective of this article. First, we'll look at the seven additive manufacturing processes and which one is the best to use. So let us begin. “Don’t be afraid to go outside of your industry to learn best practices. There might be something that surprises you or inspires you to try in your line of work.” – Emily Desimone, Director of Global Marketing at SLM Solutions Additive Manufacturing Processes There are numerous diverse additive manufacturing processes, each with its own set of standards. Here are the seven additive manufacturing procedures that many manufacturers consider based on their benefits from each process, or whichever approach best suits their product requirements. Material Jetting This additive manufacturing process is quite similar to that of conventional inkjet printers, in which material droplets are selectively placed layer by layer to build a three-dimensional object. After completing a layer, it is cured with UV radiation. VAT Photo Polymerization This procedure employs a technology called photo polymerization, in which radiation-curable resins or photopolymers are utilized to ultraviolet light to generate three-dimensional objects selectively. When these materials are exposed to air, they undergo a chemical reaction and solidify. Stereo lithography, Digital Light Processing, and Continuous Digital Light Processing are the three primary subcategories. Binder Jetting Binder jetting is a process that deposits a binding agent, typically in liquid form, selectively onto powdered material. The print head deposits alternating layers of bonding agent and construction material and a powder spreader to create a three-dimensional object. Material Extrusion S. Scott Crump invented and patented material extrusion in the 1980s using Fused Deposition Modeling (FDM). The continuous thermoplastic filament is fed through a heated nozzle and then deposited layer by layer onto the build platform to produce the object. Powder Bed Fusion Powder bed fusion procedures, particularly selective laser sintering, were the pioneers of industrial additive manufacturing. This approach melts the powdered material and fuses it using a laser or electron beam to form a tangible item. The primary kinds of powder bed fusion are direct metal laser sintering, selective laser sintering, multi-jet fusion, electron beam melting, selective laser melting, and selective heat sintering. Sheet Lamination Sheet lamination is a catch-all term encompassing ultrasonic additive manufacturing, selective deposition lamination, and laminated object manufacturing. All of these technologies stack and laminate sheets of material to form three-dimensional objects. After the object is constructed, the parts' undesirable areas are gradually removed layer by layer. Directed Energy Deposition Directed energy deposition technology employs thermal energy to melt and fuse the materials to form a three-dimensional object. These are pretty similar to welding processes, but are much more intricate. Which Additive Manufacturing Process is best? Why? Based on three fundamental factors, additive manufacturing techniques are categorized into seven types. First, the way material is solidified is determined first by the type of material employed, then by the deposition technique, and finally by how the material is solidified. The end-user often chooses an additive manufacturing technique that best suits his requirements, followed by the explicit material for the process and application, out of the seven basic additive manufacturing processes. Polymer materials are commonly used in AM techniques because they are adaptable to various procedures and can be modified to complicated geometries with high precision. Carbon-based compounds are used to strengthen polymers. Polymers, both solid and liquid, have been widely used due to the variety of shapes, formability, and end-use qualities available. Wherever the light-activated polymer contacts the liquid's surface, it instantly solidifies. Photo polymerization, powder bed fusion, material jetting, and material extrusion are the most common additive manufacturing procedures for polymers. The materials employed in these processes can be liquid, powder, or solid (formed materials such as polymer film or filament). How BASF is Using Additive Manufacturing BASF is a chemical company. BASF, one of the world's major chemical companies, manufactures and provides a range of 3D printing filaments, resins, and powders within its extensive material portfolio. The company, well-known in the 3D printing sector, has formed major material agreements with several 3D printer manufacturers, including HP, BigRep, Essentium, BCN3D, and others. BASF went even further in 2017 by establishing BASF 3D printing Solutions GmbH (B3DPS) as a wholly-owned subsidiary to expand the company's 3D printing business. In addition, BASF stated last year that B3DPS would change its name to Forward AM. BASF's role in the 3D printing business, however, is not limited to material development. BASF has made several investments in 3D printing companies over the years, including the acquisition of Sculpteo, one of the significant French 3D printing service bureaus, last year. BASF sees 3D printing as having a bright future. With the growing popularity of professional 3D printers, all of these systems will eventually require robust, high-quality polymer materials to perform at their best – and BASF has been paving the way to becoming one of the leading solution providers. Final Words All additive manufacturing procedures are unique and helpful in their way. Still, some have additional advantages over others, such as the material used, highresolution, precision, and the ability to build complicated parts. Because of these added benefits, photopolymerization, material jetting, powder bed fusion, and material extrusion are preferred over others. Therefore, choose the AM process that is best suited to your manufacturing business and will assist you in achieving the desired final product output. FAQs What are the benefits of additive manufacturing? AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability. What is the major challenge in additive manufacturing? Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. So, this can be considered a significant challenge in additive manufacturing. What are the steps of additive manufacturing? The additive manufacturing steps are divided into four steps as below, Step1 - Design a model with CAD software Step2 -Pre-processing Step3 -Printing Step4 - Post-processing { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What are the benefits of additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "AM enables manufacturers to reduce waste, prototyping costs, and customization while conserving energy and increasing production flexibility. Additionally, it benefits the supply chain and the environment, encouraging businesses to increase their manufacturing sustainability." } },{ "@type": "Question", "name": "What is the major challenge in additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Many businesses are struggling with the current difficulty of producing large and odd-sized parts using additive manufacturing. 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How to Boost Your Manufacturing Sales: 5 Ideas to Consider by C-level Execs

Article | April 29, 2022

Manufacturing sales occur when a manufacturer sells their finished goods, which are produced from raw materials or components. At the very least, that was an apt definition before industry 4.0, digitization, and consumerization. Manufacturing sales nowadays must accomplish a great deal more. Smart manufacturing technologies accelerate innovation across all verticals, and manufacturers are making every effort to meet B2C expectations. In this article, we'll look at five great ways to enhance manufacturing sales, so that manufacturers may get back on track with stalled sales deals. 5 Tips to Boost Your Manufacturing Sales Develop an ‘inbound' Sales Mindset Most salespeople have a reputation for being pushy. How frequently have you felt compelled to acquire something that wasn't appealing to you? If you answered yes, you've probably dealt with an outbound salesperson who was pushy, interruptive, and purely focused on selling. This happens when a manufacturer suffers from 'product-focused selling syndrome.' In this case, the salesman places a stronger emphasis on the products than on the customer. Additionally, you risk showing the wrong product to the customer without knowing anything about the buyer. If you do so, you are following an outdated method that needs to be replaced. Here comes the truly unique concept of inbound manufacturing marketing. Inbound marketing outperforms outbound sales methods in terms of lead generation and has the potential to generate more productive leads. Select a Customer Relationship Management Solution Spreadsheets are backdated, and the world has gone digital. It would be best you adapt as time changes. It is possible to understand one's business requirements and choose the best CRM system that will help streamline processes and deliver results faster. Regardless of your business size, the ideal CRM software may help you maintain a competitive edge by helping you to: Track all customer interactions Maintain control over sales and marketing activities Ensure that existing clients have a positive experience Increase product and service sales Streamline communication between the sales and marketing departments Acquire and retain new customers Align Your Sales and Marketing Teams According to a Forrester study, 43% of CEOs said that misalignment cost them revenue. To increase sales, your marketing and sales teams must work in unison and collaboratively. Spend time developing interactions between these teams; it will ensure that your marketing team's efforts are actually assisting your sales team in closing business. Additionally, ensure that face-to-face time between teams is facilitated, and consider adding solutions that will assist your workers in working together and communicating more effectively. The purpose of integrating your marketing and sales teams is to foster complete transparency and a shared knowledge of their respective goals and objectives. One team cannot function effectively without the other, and keeping this in mind would help everyone to grow the business. Boost Your PR with Social Media Manufacturers should invest in PR to build brand awareness and communicate stories. Social media can help broaden your PR reach. It's best to post press releases on your company's website and then share them on Twitter and Facebook. This will help your SEO and encourage others to share your material. Make sure your website page has a “share this” option for easy syndication. Also, many manufacturing companies are not utilizing their company websites to their full potential. Using websites has a competitive advantage as it helps to enhance consumer loyalty and sales. Make an Online Interactive Product Catalog Having a PDF download of your product catalog is insufficient in today's digital age. Businesses want a catalog of products that customers can search for, explore, and analyze online. Products should not be merely posted on a page, but should be integrated into a true product database, allowing for the electronic distribution of particular product listings to prospective buyers via a link or social media. This shortens the sales cycle and provides better support for your sales team as they present products. Demonstrations of products via video would be an extra bonus for any business transaction. Final Word Manufacturing sales are influenced and shaped by market conditions, industry-specific variables, manufacturing type, and distribution mix. Manufacturers may respond to these problems and develop agile and sustainable sales strategies for the future by leveraging digital sales solutions and industry 4.0 technologies. Manufacturers can retain margins, increase customer happiness, and most crucially, grow revenue through digital manufacturing sales. A customer-centric approach prepares producers for the future of a commercialized B2B market. FAQ What are manufacturing sales? Manufacturing sales are intended to provide raw materials that can be turned into finished products to meet market demand. What are direct sales? Direct sales do not involve any intermediaries. Manufacturers or producers sell directly to B2B customers. It's a good cost-cutting strategy because the producer retains complete control over marketing, sales, and shipping. What are indirect sales? Indirect sales allow manufacturers to quickly expand their sales networks, increase brand recognition, outsource sales operations costs, and reach new consumer groups or market sectors.

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Spotlight

Bayco Products, Inc.

For 30 years, Bayco Products’ vast array of portable & corded lighting products, have been the preferred choice of professionals and discriminating consumers. The Nightstick and Bayco brands are recognized world-wide as high-performance, high-quality, high-value lighting solutions across virtually every industry.

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