Manufacturing 2020: Time to Reinvent After a Golden Decade

EWALD MUNZ| January 28, 2020
MANUFACTURING 2020: TIME TO REINVENT AFTER A GOLDEN DECADE
Generally, 2009 to 2019 were 10 golden years for manufacturers worldwide. After the swift recovery from the economic and financial crisis in 2008/09, many manufacturers have been enjoying double-digit order intake growth, increasing revenues and profits for over a decade.

Spotlight

Ellison Technologies

For 60 years, Ellison Technologies has been a provider of advanced machining solutions to North American metal-cutting manufacturers. Ellison Technologies goes beyond the traditional role of a machine tool distributor by providing an enhanced level of support. Our mission is to equip U.S. manufacturers to compete and to win, both locally and globally.

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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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Reshoring and Technology Platforms Transforming Hiring Practices in the Manufacturing Sector

Article | March 31, 2021

Everyday the supply chain is jeopardized. A freighter stuck in the Suez Canal has severe ripple effects in raw material goods making their way around the world. Trade tariffs and unpredictable consequences from COVID have encouraged many US manufacturers to reshore bringing jobs stateside. This strategy will shift the supply chain challenge to a staffing challenge. As the manufacturing industry is poised for rapid growth over the next 24 months, hiring the best workers once again becomes the top challenge. As the workforce is vaccinated and reshoring the supply chain becomes a clarion call for industry, finding the right people with the right skills forces plant managers, operations managers, and HR managers to find new and innovative recruiting strategies. FactoryFix is an online platform that matches vetted manufacturing workers with companies seeking specific skill sets. This platform sets a new standard in how small to mid-sized manufacturers hire talent across the U.S.

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What are the Risks that Manufacturing Face in the Current Times?

Article | December 30, 2021

Risk management in manufacturing has always been a top priority for manufacturers to avoid any unfortunate incidents. As a result, it is possible to create a more secure work environment for employees by conducting risk assessments and implementing remedies. “If you don’t invest in risk management, it doesn’t matter what business you’re in, it’s a risky business.” – Gary Cohn, an American Business Leader. As of 2019, the worldwide risk management market was valued at $7.39 billion, and it is expected to rise at a CAGR of 18.7% from 2020 to 2027, according to allied market research. Why is Risk Assessment Critical in Manufacturing? The manufacturing industry must have a credible risk assessment and management plan to defend itself from any breaches. Risk assessment helps firms understand the dangers they face and their implications if their systems are compromised. Hence, risk assessment is very critical in the manufacturing industry. Five Risk Assessment Principles Identify hazards/risks - Employers must examine their workers' health and safety risks. Therefore, an organization must regularly inspect its employee’s physical, mental, chemical, and biological threats. Identify who may be hurt and in what way – Identifying the personnel both full-time and part-time at-risk. Employers must also examine threats to agency and contract personnel, visitors, clients, and other visitors. Assess the risks and act accordingly - Employers must assess the likelihood of each danger causing injury. This will evaluate and lower the chance at the working space. Even with all safeguards, there is always some danger. Therefore, employers must assess if danger is still high, medium, or low risk. Get the Risks Documented - Employers with five or more employees must record the critical findings of the risk assessment in writing. In addition, register any risks identified in the risk assessment and actions to minimize or eliminate risk. This document confirms the evaluation and is used to examine working practices afterward. The risk assessment is a draft. It should be readable. It shouldn't be hidden away. The risk assessment must account for changes in working techniques, new machinery, or higher work objectives. 5 Manufacturing Risks to Consider in 2022 Accidents at Work Even if official safety policies and programs are designed, followed, and enhanced, manufacturers may endure workplace accidents and injuries. Risk assessment for workplace accidents assists in mitigating the negative impact on both employees and the organization. Environmental Mishaps Manufacturers have distinct issues regarding fuel handling and hazardous waste disposal in facilities. Sudden leaks or spills may be extremely costly to clean up and result in fines from state and federal agencies. Risk assessments for such plant accidents assist businesses in mitigating financial losses. Equipment Breakdowns Essential machinery throughout the production process might fail at any time, incurring significant repair or replacement costs. Therefore, it's critical to recognize that business property insurance may not cover mechanical issues. Risk assessment and prepayment solutions protect against equipment failures without interfering with typical company operations. Supply Chain Disruption Dependence on your supply chain may result in unintended consequences that are beyond your control. For example, if you experience downtime on the manufacturing line due to a supplier's failure to supply materials or parts, you risk losing revenue and profitability. If a disturbance to your supply chain poses a hazard, risk management can assist you in managing it more effectively by quickly identifying the risk and providing a suitable response. Operation Temporarily Suspended Depending on the severity of the weather event, a factory might be severely damaged or perhaps utterly wrecked. While major repairs or rebuilding are being undertaken, recouping lost income might be vital to the business's future profitability. Risk assessment in this area enables your organization to budget for overhead expenditures such as rent, payroll, and tax responsibilities during the period of suspension of operations. Final Words Risk management is critical in manufacturing because it enables manufacturers to comprehend and anticipate scenarios and create a well-planned response that avoids unnecessary overhead costs or delays in delivering the production cycle's final result. Manufacturing risks are undoubtedly not limited to the risks listed above and may vary according to the nature of the business and regional environmental conditions. Therefore, create a well-defined strategy to overcome threats in your business and be productive at all times. FAQ How are manufacturing business risks classified? In most cases, the business risk may be categorized into four types: strategic risk, regulatory compliance risks, operational compliance risks, and reputational risks. Why should a manufacturer conduct a risk assessment? Every manufacturing employment has risks for injury or illness. But risk evaluations can significantly minimize workplace injuries and illnesses. In addition, they assist companies in discovering strategies to reduce health and safety risks and enhance knowledge about dangers.

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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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Spotlight

Ellison Technologies

For 60 years, Ellison Technologies has been a provider of advanced machining solutions to North American metal-cutting manufacturers. Ellison Technologies goes beyond the traditional role of a machine tool distributor by providing an enhanced level of support. Our mission is to equip U.S. manufacturers to compete and to win, both locally and globally.

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