Increasing Productivity in Manufacturing

| March 13, 2020
INCREASING PRODUCTIVITY IN MANUFACTURING
In the field of manufacturing, your product, revenue, and customer satisfaction rely on streamlined and efficient operations to succeed. According to the Bureau of Labor Statistics, manufacturing holds the second-highest success rate, 48 percent of all industries. If your goal is to increase productivity, below are suggestions you can implement to get you on the right track.

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Ultrasonic Power Corporation

Ultrasonic Power is a Freeport-based, woman-owned, Illinois manufacturer serving global markets. For more than 40 years UPC has served end users and OEMs requiring precision industrial ultrasonic cleaning equipment.

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2022: The Year of Robotics Industry Expansion

Article | November 12, 2021

Robotics industry growth has accelerated rapidly across several industries. It has aided manufacturers in overcoming numerous barriers related to real-time communication, workplace safety, and overall manufacturing cost and timeliness. However, if we trace its history back to 1961 when George Charles Devol introduced the first robot, dubbed 'UNIMATE,' it has exponentially grown and utilized across sectors to make operations more effortless, precise, and faster. “As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity.” – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca. However, the industry has seen snags or difficult times due to market fluctuations, unfavorable situations, and the need to remain competitive in the drive for expansion. To thoroughly understand the robotics industry, let us examine each component that surrounds it. Industrial Robotics Global Market Size According to recent Allied Market Research studies, the global industrial robotics market was worth $37,875 million in 2016 and is expected to reach $70,715 million by 2023, rising at a 9.4% compound annual growth from 2017 to 2023. Industrial Robotics Market Analysis The global industrial robotics market is primarily driven by a global increase in labor costs, which has compelled firms to replace human labor with robots. As a result, Asia and Europe are the world's fastest-growing areas, with top companies such as ABB, Fanuc, KUKA, Kawasaki, and Yaskawa Electric Corporation headquartered in the region. The global market of robotics has been segmented by its type, industry, and function. Type Industry Function Articulated Automotive Soldering and Welding Cartesian Electrical & Electronics Materials Handling SCARA Healthcare & Medicine Assembling & Disassembling Cylindrical Rubber & Plastics Painting and Dispensing Others if any Machinery & Metals Cutting and Processing Food & Beverages Milling Precision & Optics Others if any Others if any Industries That Are Pioneering the Use of Robotics As we have observed, the global robotic market will continue to rise in the future years. Therefore, let us examine which industries will extend their use of robotics in their operations. Healthcare & Medicine Medical robots help surgeons optimize hospital logistics and free up the working staff to focus on patients. In the healthcare field, robots are revolutionizing surgery by speeding supply delivery and disinfection and freeing up time for doctors to interact with their patients. da Vinci System – A General Surgical Robot The da Vinci System is a surgical robot that focuses on a wide range of urological, bariatric, and gynecological surgical treatments. In addition, Stryker's MAKO System also specializes in orthopedic surgery, specifically partial and total knee replacements. The da Vinci SP system is cleared for use in the United States exclusively for single-port urological procedures, lateral oropharyngectomy (often referred to as radical tonsillectomy), and tongue base excision. Law Enforcement Police robots are meant to gain access to areas inaccessible or dangerous to first responders, and they are capable of manipulating items and gathering data using several technologies. It encompasses robots capable of operating in various conditions and displaying a range of data and communication capabilities. Agriculture & Food Industry Farm equipment is now routinely equipped with sensors that utilize machine learning and robotics to identify weeds, compute the appropriate quantity of herbicide to spray, or learn to detect and pick strawberries, for instance. Additionally, in the food business, robotics has been used to do repetitive tasks such as picking and placing food items and cutting and slicing food items during any given food item. For instance, the modern bakery business uses robotics to perform traditional craft skills and produce any product in large quantities while maintaining high quality and hygiene standards. Transportation The transportation sector is highly leveraging robotics. The powerful transport capability, advanced control technology, and sensing precision are some of the benefits that make the transportation robots widely utilized in this sector. These benefits from robotics help the sector convey various commodities in factories, restaurants, and medical institutions, among other locations. Manufacturing Robots are employed in manufacturing to do repeated jobs and streamline the overall assembly process. Additionally, robots and humans can also collaborate on product making. Robots can replace humans for hazardous tasks or processes that need large quantities of materials, which might be hazardous for a human employee to handle. Factors Sustaining the Growth of the Robotics Industry Reduces Manufacturing Costs: Robotics application in all industries reduces the overall manufacturing process running costs. Improves Product Quality: The precision of robotics throughout the manufacturing process helps produce high-quality items that meet target client needs. Offers Competitive Market: Increased income due to utilizing the benefits of robotics applications makes any industry more competitive. Speed-ups Production Time: Robotics speeds up production and helps manufacturers increase output. Offers Task or Process Flexibility: Robotics can weld, cast, mold, assemble, machine, transfer, inspect, load, and unload items, among other duties. So, it gives the manufacturer process flexibility. Reduces Excessive Use and Waste of Production Materials: Robotics employs the exact quantity of material required for the manufactured product, reducing waste and overuse of materials. Offers a Safe Working Place: Robotics improves employee health and safety by performing tasks that humans find risky. For example, in the chemical industry, a human employee may not do a hazardous task. In such instances, robots can replace people. Final Words The rise of the robotics industry has accelerated dramatically, and it is now spreading its wings across industries. Research firm IDC provided a projection for the commercial robot market, forecasting that the market will exceed $53 billion by 2022, with a compound annual growth rate of more than 20%. In addition, several advantages of robotics such as safety, productivity, uniformity, and perfection are pushing its expansion and making it an essential element of industry 4.0. FAQs Why are robots the future of the manufacturing industry? The use of robots in manufacturing has improved process efficiency and product quality. As a result, robots are gaining favor in production and becoming the future of manufacturing. Which industries make the most use of robotics? Healthcare, agriculture, food, and manufacturing are the industries that are embracing robotics to get the most out of it. How is manufacturing utilizing robotics? Manufacturing uses robotics for repetitive tasks. This helps in the reduction of errors and human efforts. It also improves production efficiency. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "Why are robots the future of the manufacturing industry?", "acceptedAnswer": { "@type": "Answer", "text": "The use of robots in manufacturing has improved process efficiency and product quality. As a result, robots are gaining favor in production and becoming the future of manufacturing." } },{ "@type": "Question", "name": "Which industries make the most use of robotics?", "acceptedAnswer": { "@type": "Answer", "text": "Healthcare, agriculture, food, and manufacturing are the industries that are embracing robotics to get the most out of it." } },{ "@type": "Question", "name": "How is manufacturing utilizing robotics?", "acceptedAnswer": { "@type": "Answer", "text": "Manufacturing uses robotics for repetitive tasks. This helps in the reduction of errors and human efforts. It also improves production efficiency." } }] }

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This Is How You Can Lower Your Manufacturing Overhead

Article | December 21, 2021

When it comes to developing a budget for the following financial year of your manufacturing business, many operations managers start with direct labor and material expenditures. But, what about manufacturing overhead costs? Manufacturing overhead is any expense not directly tied to a factory's production. Therefore, the indirect costs in manufacturing overhead can also be called factory overhead or production overhead. Outsourcing and globalization of manufacturing allows companies to reduce costs, benefits consumers with lower-cost goods and services, and causes economic expansion that reduces unemployment and increases productivity and job creation. – Larry Elder So, this article focuses on some highly effective overhead cost reduction methods that would help you build a healthy budget for the following year. Manufacturing Overhead Costs: What Is Included? Everything or everyone within the factory that isn't actively producing items should be considered overhead. The following are some of the variables that are considered overhead costs: Depreciation of equipment and productionfacilities Taxes, insurance, and utilities Supervisors, maintenance, quality control, and other on-site personnel who aren't producing signs Indirect supply from light bulbs to toilet paper is also included in the overhead cost. Manufacturing Overhead Costs: What Is Excluded? Everything or everyone within or outside the factory that is actively producing items should be excluded from the overhead costs. Factory overhead does not include the following: Product materials Employee costs for those making the goods daily External administrative overhead, such as a satellite office or human resources Costs associated with C-suite employees Expenses associated with sales and marketing - include pay, travel, and advertising How to Calculate Overhead Costs in Manufacturing To know the manufacturing overhead requires calculating the manufacturing overhead rate. The formula to calculate the manufacturing overhead rate i.e. MOR is basic yet vital. To begin, determine your overall manufacturing overhead expenses. Then, add up all the monthly indirect expenditures that keep manufacturing running smoothly. Then you can calculate the Manufacturing Overhead Rate (MOR). This statistic shows you your monthly overhead costs as a percentage. To find this value, divide Total Manufacturing Overhead Cost (TMOC) by Total Monthly Sales (TMS) and multiply it by 100. The final formula will be: Assume your manufacturing overhead expensesare $50,000 and your monthly sales are $300,000. You get.167 when you divide $50,000 by $300,000. Then increase that by 100 to get your monthly overhead rate of 16.7%. This means your monthly overhead expenditures will be 16.7% of your monthly income. Being able to forecast and develop better solutions to decrease production overhead. Five Ways to Reduce Manufacturing Overhead Costs A variety of strategies may be used by manufacturing organizations to reduce their overhead costs. Here is a summary of some of the most important methods for reducing your manufacturing overhead costs. Value Stream Mapping – A Production Plant Process Layout A value stream map depicts the entire manufacturing process of your plant. Everything from raw material purchase through client delivery is detailed here. The value stream map provides you with a complete picture of the profit-making process. This overhead cost-cuttingmethod is listed first for a reason because every effort to reduce manufacturing overhead costsstarts with a value stream map. Lean manufacturingis also one of the techniques of eliminating unnecessary time, staff, and work that is not necessary for profit and has gained undue favor in the manufacturing process. You must first create a value stream map of the whole manufacturing process for this technique to work. Once the lean manufacturing precept is established, the following strategies for decreasingmanufacturing overhead expenses can be examined. Do Not Forget Your Back Office Management Before focusing on factory floor cost reduction techniques, remember that your back offices, where payment processing and customer contacts occur, may also be simplified and increase profitability. Fortunately, automation can achieve this profitability at a cheap cost. Manufacturers increasingly use robotic process automation (RPA) to sell directly to customers rather than rely on complex supply networks. This automation eliminates costly human mistakes in data input and payment processing by automatically filling forms with consumer data. Moreover, the time saved from manual data input (and rectifying inevitable human errors) equates to decreased labor expenses and downtime. Automating Your Manufacturing Plant For a long time, manufacturers saw factory automation as a game-changer. As a result, several plant owners make radical changes in their operations using cutting-edge technologydespite knowing it realistically. Over-investing in technologies unfamiliar to present industrial personnel might be deemed a technology blunder. Investing in new technology that doesn't generate value or is too hard for current staff to use might be a mistake. It's usually best to start small when implementing newtechnology in manufacturing. Using collaborative robots in production is one way to get started with automation. They are inexpensive, need little software and hardware, and may help employees with mundane, repeated chores that gobble up bandwidth. It is a low-cost entry point into automation that saves labor expenses and opens the door for further automation investments when opportunities are available. Reuse Other Factory Equipment and Supplies Check with other factories to see if they have any unused equipment or supplies that may be "redeployed" to your manufacturing plant. Redeployment would save you time and money by eliminating the need to look for and install new equipment while lowering your overhead costs. Outsourcing a fully equipped factory, equipment, or even staff can also assist in lowering overhead costssince you will only pay for what you utilize. As such, it is a viable method to incorporate into your production process. Employ an In-house Maintenance Expert An in-house repair technician can service your equipment for routine inspections, preventive maintenance, and minor repairs. This hiring decision might save money on unforeseen repair expenses or work fees for an outside repair provider. Having someone on-site who can do emergency repairs may save you money if your equipment breaks after business hours. Final Words Manufacturing overhead costis an essential aspect of every manufacturing company's budget to consider. Smart manufacturingis intended to be productive, efficient, and cost-effective while effectively managing production expenditures. Calculating the manufacturing overheadcan provide you with a better understanding of your company's costs and how to minimize them. Depending on the conditions or geographical needs, each manufacturing plant's overhead expensesmay vary. As a result, identify your production overhead costsand concentrate on reducing and improving them. FAQ What are manufacturing overheads? Manufacturing overhead cost is a sum of all indirect expenses incurred during production. Manufacturing overhead expenses usually include depreciation of equipment, employee salaries, and power utilized to run the equipment. What is a decent overhead percentage? When a business is functioning successfully, an overhead ratio of less than 35 % is considered favorable. How can I calculate the cost of manufacturing per unit? The overall manufacturing cost per unit is determined by dividing the total production expenses by the total number of units produced for a particular time.

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Three Business Examples That Effectively Practice Lean Manufacturing

Article | December 13, 2021

Lean manufacturing principles enable manufacturing businesses to achieve spectacular results and overhaul their conventional operations. A wide range of industries have adopted lean manufacturing because of its enormous advantages, and they have seen excellent results as a result. The 2010 Compensation Data Manufacturing survey indicated that 69.7% of manufacturing organizations employ lean manufacturing principles. By consuming this data, we can understand how far organizations have progressed toward incorporating lean principles into their operations. “Many companies are not willing to change or think they are done once they make a change. But the truth is technology, consumer demands; the way we work, human needs, and much more are constantly changing.” –Michael Walton, Director, Manufacturing Industry Executive at Microsoft Let's look at some examples of lean manufacturing from some well-known companies. These leading-edge examples of lean manufacturing will shed light on how lean principles positively affect. Leading Companies Using Lean Manufacturing Effectively Successful manufacturing businesses like Toyota, Nike, and Caterpillar are currently employing lean manufacturing ideas in their production processes. In addition, Intel, Parker Hannifin, and John Deere embrace these techniques. From them, we've described three different organizations in various sectors that are successfully adopting lean manufacturing. JOHN DEERE John Deere has also implemented a lean manufacturing strategy. As a result, many of their quality control procedures are automated, which means that more components can be checked for flaws in less time. This means that more supply can be released each day, and the product can be supplied at a lower price to the consumer. Additionally, these controls monitor the manufacturing process for each component of their products, ensuring that they never manufacture more than is required and waste essential materials in the process. INTEL Intel, known for its computer processors, has used lean manufacturing techniques to provide a higher quality product for an industry that requires zero defects. In the past, it took more than three months to get a microprocessor to the manufacturer, but this principle has helped shorten that time to less than ten days. Intel rapidly learned that creating more but worse quality was not the way to raise revenues and increase consumer satisfaction with its products, which were extremely precise and technical. Instead, both parties gain from quality control and waste reduction initiatives. This is even true in the tech industry, where goods are constantly changed and upgraded. TOYOTA Toyota, the world's largest automaker, was the first to implement lean manufacturing in its manufacturing operations. But, even more importantly, they've learned how to limit products that don't match customer expectations by eliminating waste. To achieve these goals, Toyota employs two essential procedures. The first is a method known as Jidoka, which loosely translates as "automation with the assistance of humans." This implies that, although some of the work is automated, humans always ensure that the result is of the highest quality. When something goes wrong, the machines have built-in programs that allow them to shut themselves down. Known as the Just In Time (JIT) model, this is the second stage. Once the last part of a process has been finished, the next phase can begin. No unnecessary work will be done if there is a problem with the assembly line. This lean manufacturing technique has inspired thousands of other businesses. Final Words Lean manufacturing principles and their execution require discipline and patience to get the results out of them. When we see the successful lean manufacturing examples, it is not a fraction of a second success. They have devoted their time, energy, and efforts to modifying every single operational process in order to become a part of lean manufacturing. Lean manufacturing is not a method; it is a way of life that transforms your business practices and takes your firm to a new level of operations. Gain insights from renowned organizations' lean manufacturing success stories to help you become a part of the lean companies of 2022. FAQ What is the effect of lean manufacturing? Lean is a performance-based, continuous-improvement strategy that removes waste and unnecessary processes from organizational operations. As a result, your company becomes more focused on the results. Is it possible for lean manufacturing to fail? It is conceivable in some circumstances, such as failing to focus on a single system implementation or implementing too many system changes at once and failing to have a sound follow-up system to check that everything is working effectively. Why do certain businesses struggle with lean manufacturing? Most businesses fail to see that lean is a management philosophy, not a set of tools. As a result, most corporate leaders either don't understand or lack the patience and control to implement lean manufacturing. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What is the effect of lean manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Lean is a performance-based, continuous-improvement strategy that removes waste and unnecessary processes from organizational operations. As a result, your company becomes more focused on the results." } },{ "@type": "Question", "name": "Is it possible for lean manufacturing to fail?", "acceptedAnswer": { "@type": "Answer", "text": "It is conceivable in some circumstances, such as failing to focus on a single system implementation or implementing too many system changes at once and failing to have a sound follow-up system to check that everything is working effectively." } },{ "@type": "Question", "name": "Why do certain businesses struggle with lean manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Most businesses fail to see that lean is a management philosophy, not a set of tools. As a result, most corporate leaders either don't understand or lack the patience and control to implement lean manufacturing." } }] }

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Top Electronics Manufacturing Trends to Watch in 2022

Article | October 13, 2021

The electronics manufacturing business is adopting new technologies to create smart electronics manufacturing products for its consumer base. Next-generation technologies are shaping the future of the manufacturing industry by enabling it to create technologically advanced and user-friendly products. Matt Mong, one of the manufacturing industry's leading professionals, stated in an interview with Media7, “Be Different. Don’t position your product in an existing category. Instead, create your category and make the competition irrelevant and obsolete.” – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca. The year 2022 will be a year of advancement and development for the electronics manufacturing industry. So, manufacturers are eager to embrace new technologies and produce more innovative, more user-friendly goods that become part of consumers' daily lives and meet their needs. To make the manufacturing process manageable and deliver advanced products, we will look at the top five trends flourishing in the electronics manufacturing industry. Top Five Electronics Manufacturing Industry Trends Future manufacturing technologies are transforming the electronics manufacturing industry's processes and products. Let's look at the top electronics manufacturing industry trends for 2022, which will propel the sector to new heights of technological advancement. Utilizing the Benefits of the Internet of Things The Internet of Things is being used in both the manufacturing process and the products themselves. It enables electronic manufacturing products and processes to become more intelligent and performance-driven to fulfill business and customer needs. In electronics manufacturing, the Internet of Things (IoT) enables businesses to solve common production challenges such as product quality issues, changing demands, and a complex global supply chain. As a result, it increases productivity and efficiency while reducing human effort. Industrial units may gather and analyze real-time data and processes using IoT-based sensor systems. Additionally, it assists organizations in managing data and transforms traditional manufacturing into an intelligent manufacturing unit. Using an ERP System to Maintain the Company's Competitive Edge ERP (Enterprise Resource Planning) is a centralized management system for all operational and business activities. The software automates all manufacturing processes and enables the electronics manufacturing sector to achieve higher precision throughout the manufacturing process and product delivery. ERP has the potential to boost productivity, improve efficiency, decrease expenses, and increase profitability. ERP enables electronics manufacturers to forecast, plan, modify, and respond to changing market demands. By using an ERP system in your manufacturing unit, you may expand your business and increase revenue. Making Use of Big Data The electronics manufacturing industry benefits from the use of big data to make critical business decisions. It aids in the integration of previously isolated systems to provide a comprehensive view of industrial processes. It also automates data gathering and processing, allowing for more excellent knowledge of each system individually and collectively. Big data also assists manufacturers in discovering new information and identifying trends, allowing them to optimize operations, improve supply chain efficiency, and find variables that impact manufacturing quality, volume, or consistency. In addition, big data assists the electronics manufacturing industry in keeping up with the rapidly changing digital world. Using AR and VR to Create Consumer-friendly Goods AR and VR are future manufacturing technologies that are changing electronics manufacturing products and driving growth. Robotics is a crucial usage of virtual reality in electronics production. Manufacturers may use powerful virtual reality software to design goods. This implementation of virtual reality software reduces production errors and saves time and money. AR in electronics manufacturing allows product developers to generate interactive 3D views of new products before production. AR and VR are part of Industry 4.0, the digital revolution of conventional electronics production units. Adoption of 3D Printing on a Wide Scale One of the essential advantages of today's electronics 3D printing is that companies can quickly prototype PCBs and other electrical devices in-house. In addition, 3D printing has simplified the electronics manufacturing process, and it is currently being utilized to manufacture multilayer printed circuit boards. It uses material jetting technology to spray conductive and insulating inks onto the printing surface. Let's look at an example of an analogy that worked for Jinzhenyuan - The Electronic Technology Co. Ltd., managed by Mr. Huang Runyuan, Jinzhenyuan's General Manager, and based on the concept of Industry 4.0. (Reference: Forbes) Jinzhenyuan - The Electronic Technology Co. Ltd. Takes a Significant Step Forward with Industry 4.0 Jinzhenyuan - The Electronic Technology Co. Ltd., formed in 2012, sells its products globally. In addition, it manufactures cellphones, computers, cars, and a variety of other consumer electronics. Due to changing market needs, the firm planned to upgrade its production facility to industry 4.0 by the end of 2017 to participate in smart manufacturing. The company increased production efficiency, shortened production cycles, and cut costs due to the digital revolution. Today, Jinzhenyuan is regarded as a model of digital transformation in the community in which it works. Let’s observe the statistics for Jinzhenyuan following the deployment of Industry 4.0. 32% improvement in total production efficiency 33% cost reduction 41% decrease in R&D to production cycles 51% reduction in substandard parts rate – from 3,000 to 1,500 per million Final Words The electronics manufacturing sector is on the verge of a digital revolution that will improve the production process efficiency and cost-effectiveness. Many of the world's biggest firms, like Apple, Microsoft, Hitachi, and Saline lectronics, are developing future agile factories to keep up with the world's digital transformation. Future manufacturing technology will help your manufacturing company make the manufacturing process more efficient and boost the business revenue. FAQs What are the future electronics technologies? Smart grid solutions, wearable technology devices, prefabricated goods, the Internet of Things, and robots are some of the future electronics innovations that will propel the business forward. Is the supply chain benefiting from new technology trends? Yes, supply chain management benefits from smart technology as well. Trucks equipped with cutting-edge technologies can get real-time data on the weather and road conditions ahead of time. It contributes to the supply chain process's reduction of possible risks. Which manufacturers are implementing the industry 4.0 concept in their factories? Whirlpool, Siemens, Hirotec, Tesla, Bosch, and Ocado, among others, have turned their traditional factories into digitally smart ones that incorporate all of the cutting-edge technology necessary to improve and optimize the production process. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What are the future electronics technologies?", "acceptedAnswer": { "@type": "Answer", "text": "Smart grid solutions, wearable technology devices, prefabricated goods, the Internet of Things, and robots are some of the future electronics innovations that will propel the business forward." } },{ "@type": "Question", "name": "Is the supply chain benefiting from new technology trends?", "acceptedAnswer": { "@type": "Answer", "text": "Yes, supply chain management benefits from smart technology as well. Trucks equipped with cutting-edge technologies can get real-time data on the weather and road conditions ahead of time. It contributes to the supply chain process's reduction of possible risks." } },{ "@type": "Question", "name": "Which manufacturers are implementing the industry 4.0 concept in their factories?", "acceptedAnswer": { "@type": "Answer", "text": "Whirlpool, Siemens, Hirotec, Tesla, Bosch, and Ocado, among others, have turned their traditional factories into digitally smart ones that incorporate all of the cutting-edge technology necessary to improve and optimize the production process." } }] }

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Spotlight

Ultrasonic Power Corporation

Ultrasonic Power is a Freeport-based, woman-owned, Illinois manufacturer serving global markets. For more than 40 years UPC has served end users and OEMs requiring precision industrial ultrasonic cleaning equipment.

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