Article | January 20, 2022
COVID drove many supply chain disruptions in 2021. This was particularly true for companies using Asia to source product. Sadly, the bottleneck continues in 2022, but there are new channels now available to serve the North American material handling market. System integrators, dealers, and distributors in the space cannot work with vendors who offer slow delivery timetables. Customers want shelving, racking, conveyors, and robotics no later than Q3 2022.
MODEX 2022 provides answers to solve the supply chain disruption
MODEX 2022 (March 28-31, 2022) in Atlanta, will once again bring many global manufacturers to the event. Nearly 800 exhibitors and 40,000 attendees will respect COVID health and safety protocols while learning about much needed solutions from a variety of global manufacturers. For the first time there is an African company exhibiting at MODEX: LinkMisr International.
Article | 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!
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Many manufacturers leave performance on the table due to outdated processes and programming.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.
Article | December 23, 2021
Every manufacturing company aims to be as efficient as possible to maximize profit. However, it's difficult to determine where you stand and what targets to establish unless you can precisely measure your efficiency. Manufacturing KPIsplay an important role in this process.
Keeping track of many indicators without considering their commercial worth is a waste of time.
“Not everything that can be counted counts and not everything that counts can be counted”
- Albert Einstein
But connecting goals to measurements is a certain way to track progress and improve processes. So let's get started with how to choose the most appropriate key performance indicators(KPIs) for your business.
Manufacturing KPI 2022: How to Choose the Right One?
Why are KPIs called “Key” Performance Indicators? While any statistic can be used to assess performance, KPIs are the most critical. Hence they are called key performance indicators. Companies' priorities while selecting their company KPIs may differ substantially depending on the industry in which they operate.
“Strategic-operational KPIs alignment gives the organization a powerful tool to use when implementing change.”
― Pearl Zhu
A corporation should not track more than ten manufacturing KPIs to avoid overblowing processes. So, manufacturing efficiency, customer satisfaction, lead times, etc., should all be included.
Depending on your business nature, you must select your KPIs. However, each of those indicators must meet a set of criteria before being considered meaningful.
So, what is a decent KPI for manufacturing?
It gives objective and clear data on progress toward a certain goal
It measures efficiency, quality, punctuality, and performance
It allows for tracking performance over time
It helps in decision making
It should be the one that matches the company's long-term objectives
It has to be measurable and quantifiable
It must be realistic and actionable
Following that, let's have a look at the most important manufacturing KPIs for 2022, which will assist you in better understanding your manufacturing business and formulating a growth strategy in line with that understanding.
Most Critical Manufacturing KPIs in Order of Priority
Despite the fact that manufacturers should also monitor general key performance indicators (KPIs) such as sales revenue, net profit margin, and so on, the manufacturing business demands the tracking of specific manufacturing metrics. Below are some of the most important manufacturing key performance indicators (KPIs).
Using this manufacturing KPI metric, you can see how much value there is in products still in progress. It assists manufacturing organizations in determining how much of their working capital is locked up in incomplete products and can aid in identifying supply chain managementdifficulties.
You can compute the Work-In-Progress (WIP) by using the formula provided below.
Return on Assets
This manufacturing KPIseems to be more about financing than manufacturing. Yes, it does. However, financial measurements are just as vital as production ones. A firm cannot exist unless it generates revenue, and this indicator measures how efficiently your company uses its assets and generates revenues.
The Return on Assets (ROA) of your company can be calculated using the formula below.
Cost Per Unit
It is critical to understand the overall manufacturing cost per unit. You can't appropriately price a product without it. This manufacturing KPIdivides total manufacturing costs by the number of units produced. Materials, overhead, depreciation, and labor are standard costs.
Companies utilize this manufacturing statisticto forecast future raw material needs to satisfy client demand. Unfortunately, this statistic is more challenging to employ because it is mainly dependent on unpredictable external circumstances. The basic formula is:
The seasonal factors are distinct
Average demand is calculated as:
A company's lead time, also known as order cycle time, is an important KPI. It shows how swiftly your organization processes orders and meets client requests. It is time it takes to complete an order from confirmation to delivery.
Long lead times can imply process inefficiencies that produce bottlenecks and excessive expenses. Conversely, short lead times are important since they allow you to respond to consumer needs swiftly and efficiently.
The total lead time can be divided into smaller segments as follows:
The time it takes to manufacture a product from start to finish
The time it takes to deliver a product from stockto a client
The time it takes suppliers to deliver products to manufacturers
By segmenting the lead time, you may more precisely identify the areas where inefficiencies in the process occur.
Toyota’s Four Key Performance Metrics
As a company, Toyota places a high focus on environmental protection. Toyota's vehicles are designed to use less fuel and produce less waste.
Regardless of the company's size, Toyota is committed to protecting the environment. Toyota's 'Earth Charter' was created in 1992 as part of the company's Global Policy initiative. It was Toyota's first overseas facility and the UK's first ISO14001-certified car manufacturer. Waterborne paints were utilized for the first time and zero waste was sent to landfills. In 2009, Toyota Manufacturing UK did not use any incinerators.
Toyota has developed a set of key performance indicators (KPIs) for each of its major production areas. There are four key performance metrics: energy, water, waste, and volatile organic compounds (VOCs).
Since its start in 1992, Toyota Manufacturing UK has attempted to mitigate its environmental impact. The figure below illustrates the environmental KPIsfor the Burnaston plant. Each year, Toyota sets new goals to improve its results.
79% reduction in vehicle energy consumption
62% reduction in waste per car
76% reduction in VOC emissions per car
79% reduction in water consumption per vehicle
You can use the aforementioned manufacturing KPIsto construct your manufacturing KPI template, but keep in mind that the manufacturing metricsyou need to track may differ from those listed here. The first prudent move any business can make while examining its operation is to identify and track the relevant KPIs. Also, in manufacturing, there are several different KPIs, phrases, and abbreviations need to be understood and used where it makes the most sense.
What is manufacturing KPI?
A manufacturing Key Performance Indicator (KPI) or metric is a well-defined and measurable indicator that the manufacturing sector uses to evaluate its performance over time and compare it to that of other industries.
What are the key KPIs for manufacturers?
On-Time Delivery, Production Schedule Attainment, Total Cycle Time, Throughput, Capacity Utilization, and Changeover Time are some of the key manufacturing KPIs.
Article | December 6, 2021
Aerospace manufacturing and design are getting advanced with additive manufacturing. However, the limitations of traditional manufacturing techniques sometimes make it incompetent to produce technologically oriented products. Additive Manufacturing (AM)helps the aircraft system run more efficiently by creating lightweight aircraft parts.
This is one of the reasons that additive manufacturing is gaining traction in aerospace and other industries. According to recent analysis and data, the global additive manufacturing market is expected to grow from USD 9.52 billion in 2020 to USD 27.91 billion in 2028. The expanding technologies and materials used in additive manufacturing will indeed stimulate industry growth shortly.
It’s important to note that there isn’t one channel that is the silver bullet. Most of the time, a combination of different channels will help drive a more powerful outcome.”
– Wendy Lee, Director of Marketing at Blue Prism
However, the aerospace industry encounters some challenges with additive manufacturing, which is the focus of this article. Scalability, multi-material capabilities, professional workers, high-cost materials, and quality compliance norms are all constraints that aerospace professionals are dealing with. Here we will discuss the top three challenges of additive manufacturing in aerospace and their solutions.
Future of Additive Manufacturing in the Aerospace Industry
Even though additive manufacturing has been around for a while, it has only lately become advanced enough to be used in the aerospace sector.
In the aerospace business, additive manufacturing has the potential to deliver significant benefits. Cost savings, design freedom, weight reduction, shorter time to market, fewer waste materials, better efficiency, and on-demand production are just some of the benefits.
Although additive manufacturing cannot make every part, it provides an exciting opportunity to explore feasible alternatives, either supplementing or replacing traditional manufacturing processes. However, it must be taken into account early in the development phase. Additionally, knowledge must be embedded in aircraft design teams to ensure the successful use of additive manufacturing.
However, in recent years, AM has become more prevalent in end-to-end manufacturing. According to Deloitte University Press, the future of AM in aerospace may include:
Directly embedding additively produced electronics
3D printing engine parts
Making battlefield repair components
Top 3 Additive Manufacturing Challenges in the Aerospace Industry and Solutions
While problems are inherent in any new technology, experts overcome them by identifying solutions. Let's look at the top three challenges that the aerospace industry is currently facing and the solutions to overcome them.
Lack of Qualified Experts
Using 3D printers in production and automating work processes are skills that are lacking. However, the obstacles are natural, and the skilled manufacturing workforce is aging and reluctant to adapt to new design models. This is creating the skills gaps surrounding manipulating AM technology.
How to Overcome
Less time spent educating employees is better for business. For example, the US National Additive Manufacturing Institute and the European ADMIRE initiative offer accelerated courses via remote learning websites.
Of course, you'll need to provide numerous additive manufacturing opportunities to attract the key technologists, either on-site or off-site. They will oversee new hires' activities and help them translate their knowledge of 3D printing into designs and final items.
Over Budget Material
The typical cost of AM equipment is $300,000. Industrial consumables cost between $100 and $150 per item (although the final price is formed after choosing the material; plastic, for example, is the most budget-friendly option).
How to Overcome
To overcome this obstacle, you must plan a long-term implementation strategy based on the manufacturing-as-a-service model. On-demand manufacturing reduces manufacturing costs and speeds up product development. You can also go with cheap 3D printers that use cheap welding wire that hasjust come onto the market. They cost $1,200 and may suit your needs.
Fresh Quality Compliance Guidelines
As 3D printing and CNC manufacturing technologies constantly evolve, there are no established norms or regulations for 3D printed objects. However, 3D printed solutions do not always match traditional quality, durability, and strength. For example, a 3D-printed mechanical part. Can someone order 500 similar parts a few months later? Consistency standards and product post-processing may have a negative impact in such circumstances. So, in such a case, traditional manufacturing wins over 3D printing.
How to Overcome
You might endeavor to set quality criteria for your 3D-printed products to ensure they are comparable to traditional ones. You can also apply the ANSI AMSC and America Makes standards, which define quality criteria for 3D printed products.
How Boeing Applies Additive Manufacturing Technology?
Boeing is focusing its efforts on leveraging and speeding up additive manufacturing to transform its manufacturing system and support its growth. The company operates 20 additive manufacturing facilities worldwide and collaborates with vendors to supply 3D-printed components for its commercial, space, and defense platforms.
Boeing is now designing missiles, helicopters, and airplanes using 3D printing technology. A small internal team contributes roughly 1,000 3D-printed components to the company's flight projects. Boeing claims that addressing design as an "integrated mechanical system" considerably improves manufacturability and lowers costs.
Additive manufacturing is altering the way the aerospace industry designs and manufactures aircraft parts. Aerospace advanced manufacturing is making aircraft production easier. We've explored solutions to some of the snags that you may encounter. However, other concerns, such as limited multi-material capabilities and size constraints, require solutions, and industry specialists are working on them. Despite these challenges, additive manufacturing is still booming and rocking in a variety of industries.
Why is additive manufacturing used in Aerospace?
It allows the industry to build quality parts quickly and inexpensively. Reduce waste and build parts for aircraft that are difficult to manufacture using existing methods.
How does additive manufacturing help in Aerospace applications?
Environmental control system (ECS) ducting, custom cosmetic aircraft interior components, rocket engine components, combustor liners, composite tooling, oil and fuel tanks, and UAV components are examples of typical applications. 3D printing helps in producing solid, complicated pieces with ease.
Which aerospace firms use additive manufacturing/3D printing?
Boeing and Airbus are two of the many aircraft businesses that use additive-created parts in their planes. Boeing incorporates additive manufacturing (AM) components into both commercial and military aircraft. Airbus also employs AM metal braces and bleed pipes on the A320neo and A350 XWB aircraft.
"name": "Why is additive manufacturing used in Aerospace?",
"text": "It allows the industry to build quality parts quickly and inexpensively. Reduce waste and build parts for aircraft that are difficult to manufacture using existing methods."
"name": "How does additive manufacturing help in Aerospace applications?",
"text": "Environmental control system (ECS) ducting, custom cosmetic aircraft interior components, rocket engine components, combustor liners, composite tooling, oil and fuel tanks, and UAV components are examples of typical applications. 3D printing helps in producing solid, complicated pieces with ease."
"name": "Which aerospace firms use additive manufacturing/3D printing?",
"text": "Boeing and Airbus are two of the many aircraft businesses that use additive-created parts in their planes. Boeing incorporates additive manufacturing (AM) components into both commercial and military aircraft. Airbus also employs AM metal braces and bleed pipes on the A320neo and A350 XWB aircraft."