Home > Resources > Articles > This Is How You Can Lower Your Manufacturing Overhead

This Is How You Can Lower Your Manufacturing Overhead

Bhagyashri Kambale | December 21, 2021
MANUFACTURING OVERHEAD COST
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 production facilities
  • 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 expenses are $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-cutting method is listed first for a reason because every effort to reduce manufacturing overhead costs starts with a value stream map.

Lean manufacturing is 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 decreasing manufacturing 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 technology despite 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 new technology 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 costs since 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 cost is an essential aspect of every manufacturing company's budget to consider. Smart manufacturing is intended to be productive, efficient, and cost-effective while effectively managing production expenditures. Calculating the manufacturing overhead can 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 expenses may vary. As a result, identify your production overhead costs and 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.

Spotlight

Tesmec

Tesmec Group is leader in designing, manufacturing and selling of systems, technologies and integrated solutions for the construction, maintenance and efficiency of infrastructures related to the transport and distribution of energy, data and material. STRINGING: designing, manufacturing and supplying machines and accessories for stringing operations and equipment for the construction and maintenance of infrastructures for energy transport and distribution.

OTHER ARTICLES

Is Additive Manufacturing the Key to Restore American Manufacturing?

Article | November 20, 2021

Additive manufacturing in America plays a significant part in reviving the manufacturing industry and establishing the country as a leader in applying additive manufacturing technology. The United States was formerly the industrial leader, but it fell out of favor between 2000 and 2010 for many reasons, including recession and structural and financial instability. In this challenging time, technology interventions such as additive manufacturing in the manufacturing business have allowed the industry to survive. As per the recent report by A.T. Kearney, the USA, the industry leader in manufacturing, has worked hard to reclaim its top position in manufacturing and has also been named the leader in additive manufacturing. Let's look at which fields of America are utilizing the benefits of additive manufacturing technology to reclaim its position as the industry leader. Additive Manufacturing in America The manufacturing industry is gravitating toward additive manufacturing, sometimes known as 3D printing. The numerous advantages of additive manufacturing, such as the reduction of material waste, the reduction of prototyping time, the reduction of prototyping costs, the creation of lightweight objects, and the ease with which it can be implemented and recreated, are making it more popular around the world, including in the United States. In the United States, the additive manufacturing and material industry is expected to be worth $4.1 billion by 2020. China is the world's second-largest economy and is expected to reach a projected market size of US$14.5 billion by 2027, with a CAGR of 27.2 percent from 2020 to 2027. How does America Leverage the Additive Manufacturing? US Airforce has launched research into 3D printing The US Air Force has begun researching 3D printing replacement parts for old planes utilizing a 3D printing platform. The project initiative credit goes to 3D Systems, Lockheed Martin, Orbital ATK, and Northrop Grumman. America Makes will observe the project in its third stage and be led by the University of Dayton Research. The Air Force Laboratory financed the Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS) program. The US Air Force will investigate how the 3D printing technology may reproduce components for outdated aircraft. Using additive manufacturing, the replacement parts may be created faster and in smaller batches, with no minimum order quantity. In addition, applying additive manufacturing will reduce the aircraft ground time and eliminate the need for parts warehousing. American Manufacturing Companies and Additive Manufacturing 3D Systems, Inc. 3D Systems is an additive manufacturing company. Their work goes beyond prototyping. The company's experts use their deep domain expertise in aerospace and healthcare industries to produce competitive additive manufacturing solutions. This global leader in additive manufacturing helps you define business needs, verify manufacturing flow, and scale manufacturing flow. General Electric GE has seen the benefits of additive manufacturing and its options for product design, such as the potential to build lighter, more vital components and systems. As a result, they created goods that are better performing, more sophisticated in design, and easier to produce. Ford Ford's advanced manufacturing center in Michigan is all about additive manufacturing. The company employs 3D printing extensively in product development and is looking to integrate it into manufacturing lines. As a result, additive manufacturing is now a critical aspect of the Ford product development cycle, enabling prototype parts and product engineering exercises. Final Words The American manufacturing industry has experienced a renaissance as a result of the advent of additive manufacturing. Additionally, it has built its national accelerator and leading collaborative partner in additive manufacturing, "America Makes," which is the largest manufacturing industryglobally in terms of revenue and operates in a variety of areas. However, it is mainly focused on 3D printing or additive manufacturing, which is undoubtedly reviving the country's manufacturing sector. FAQ What are the significant challenges in additive manufacturing? Limitations in terms of size, consistency of quality, scalability, a limited variety of materials and high material costs, and limited multi-material capabilities are only a few of the prevalent issues associated with additive manufacturing technology. Which company is leading in additive manufacturing technology in the USA? 3D Systems Corp. is the leading company in additive manufacturing technology with a revenue of $566.6 million. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What are the significant challenges in additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Limitations in terms of size, consistency of quality, scalability, a limited variety of materials and high material costs, and limited multi-material capabilities are only a few of the prevalent issues associated with additive manufacturing technology." } },{ "@type": "Question", "name": "Which company is leading in additive manufacturing technology in the USA?", "acceptedAnswer": { "@type": "Answer", "text": "3D Systems Corp. is the leading company in additive manufacturing technology with a revenue of $566.6 million." } }] }

Read More

Manufacturing in 2022 - Five Emerging Trends in the Industry

Article | October 8, 2021

The trends in the manufacturing industry for 2022 are expanding and altering the industry's conventional face. The future of manufacturing is going to merge with digitalization and technological applications. As a result, all operation methods, products, and manufacturing outcomes will be modernized with new technology applications. To brighten the future of manufacturing, manufacturing companies must examine new trends in the industry before developing their manufacturing plans for 2022. Technological advancements are the next game-changer in the manufacturing business. Adeaca's Vice President of Market Innovation and Project Business Evangelist had recently quoted in an interview with Media7 as, “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 The new trends in manufacturing are leveling up every part and element of the industry. In this article, we'll look at a new trend for each industry aspect that's assisting manufacturers in speeding up the production process, increasing ROI, and propelling their manufacturing business to new heights. Additionally, it will assist you in addressing current industry challenges such as forecasting product demand, addressing skilled manpower shortages, and increasing manufacturing plant efficiency. Five Manufacturing Industry Trends to Watch in 2022 Emerging trends in manufacturing provide a chance to review your production strategy for products and processes. Check out below the upcoming trends in manufacturing that are getting attention in the industry. Customer Engagement and Purchase Experience Creating an exceptional digital customer experience is a new trend in manufacturing. According to industry experts, mapping the customer journey and their interactions with your products is the first step towards establishing a positive connection with your potential consumers. A few of the most popular strategies to improve the consumer purchasing experience and engagement are as follows: Build a knowledge base for your products on your business website Create a comprehensive FAQs page that addresses all of the buyer's possible queries Create a chatbot to provide immediate help to the buyer with further inquiries Create a brand story and a comprehensive description of your manufacturing business If possible, provide product statistics and success stories, and content about consumer satisfaction with your product Create a product functionality video or explanatory picture material to familiarize the potential customer with your product These are some of the trends that engage your prospective buyers and increase their purchasing experience through a range of product-related information and educate them about you and your products. Smart Technology-enabled Products Smart is the new norm in every industry. The old operations and goods that were once a part of everyone's life have now been replaced by technology. Manufacturing is no exception to this alteration. Due to the increasing demand for smart products among customers, every company is now looking forward to inventing and manufacturing smart products. Explore and understand how you may incorporate cutting-edge technology (Artificial Intelligence, Machine Learning, Edge Computing, and Digital Twins, and more) into your products to help them stay updated with manufacturing trends. Virtual and Augmented Reality in Manufacturing (Industry 4.0) Transforming traditional manufacturing systems and processes into smart, tech-savvy ones is a new trend in manufacturing. The future of manufacturing is expected to witness this digitization in 2022 and beyond. Therefore, you must convert your conventional manufacturing plants into smart ones, i.e., as per the concept of Industry 4.0 – the fourth industrial revolution. Discover how prominent companies are implementing Industry 4.0 The following are some popular transformations that many popular manufacturing factories are adopting to become part of the industry revolution. To achieve a zero-carbon footprint, manufacturers may use analytics systems to determine the amount of trash they create and develop ways to eliminate it. (Implemented by Whirlpool) Utilize an analytics platform to decipher usage data for energy, water, and other utilities. (Implemented by Whirlpool) Utilize technology such as Siemens' Mindsphere, which enables online analysis of several aspects of a production plant and helps manufacturers create digital models using real-time data. (Implemented by Siemens) Utilize a combination of IoT and cloud-based technologies to avoid downtime and gather analytics data. (Implemented by Hirotec – a Japan based manufacturing company) Machine learning technology can be used to foretell and avoid system failures in your manufacturing plant. (Implemented by Hirotec – a Japan based manufacturing company) Utilize robotics and to accelerate manufacturing across many verticals. (Implemented by Ford) Utilize 3D printing to improve the precision of product design and to avert product defects during the early production stage. (Implemented by Aerospace: Airbus) These are some examples that other well-known manufacturing companies in the market, such as Hewlett-Packard, Ford, Whirlpool, and Siemens are currently using. So, consult an expert and determine how to leverage emerging technology to turn your production plant into a smart manufacturing unit. Internet of Things (IoT) to Boost Revenue Manufacturing companies have begun to leverage the Internet of Things to establish connectivity between machines and operational procedures throughout manufacturing. This linkage between machine and operation significantly decreases the human supervision required for each step and completely automates them. Manufacturers intend to incorporate these IoT trends in manufacturing into both their products and operational processes. IoT further enables manufacturers to operate and monitor their work remotely. As a result, they can concentrate on developing new strategies and preparing for future ventures. Shifting Focus from B2B to B2C Model Several manufacturers skip intermediaries and connect directly with their consumers to sell efficiently to their target consumer group. This purposeful approach has multiple benefits, which are outlined below. Manufacturers may skip the lengthy retail sales cycle and achieve a shorter time to market The absence of a third party between the manufacturer and the customer reduces the risk of brand misinterpretation or dilution Direct interaction with customers enables manufacturers to obtain more accurate consumer data, product feedback, and requirements for new product development Manufacturers can control the price of their products due to the absence of a third party between them and the target consumer group These benefits of the B2C model attract manufacturers and encourage them to develop added production techniques with these benefits in mind. Final Words Technology, innovation, and digitization are the future of manufacturing. The IoT trends in manufacturing are essential for industrial production and will allow the manufacturing industry to obtain a new competitive edge. Hence, manufacturers must keep in mind this industry revolution (industry 4.0 and 5.0) while developing strategies for their manufacturing operations in 2022. FAQs What are the benefits of adopting the Internet of Things in manufacturing? IoT devices can monitor industrial operations, manufacturing cycles, and other warehouse data management processes automatically. This benefit decreases the amount of time spent monitoring individual operations and increases production speed. What role will smart manufacturing play in the future? According to a grand view research analysis, the smart manufacturing market was worth USD 236.12 billion in 2020 and is expected to extend at a 12.4 percent compound annual growth rate to reach USD 589.98 billion by 2028. What are the critical components of the smart factory of the future? Robotics, the Internet of Things, big data, and cloud-based administration will be critical components of the future smart factory.

Read More

Technologies That Will Keep You Ahead in the Manufacturing Realm

Article | November 20, 2021

Modern manufacturing methods are pioneering and adopting manufacturing industry advancements. To remain competitive in the present era and provide the most excellent industry solutions to your organization and target customer group in 2022, you must employ new manufacturing technologies in your manufacturing processes. Additionally, embracing current technologies is the ideal approach to tackle the industry's current challenges such as workplace safety, digitalization of operations, and a lack of skilled workers. This article will discuss some of the leading manufacturing technologies that transform traditional manufacturing facilities into smart manufacturing factories. So, let us begin. Manufacturing Technology & Innovations for 2022 To better understand industry 4.0, let's look at some of the manufacturing technologies that will dominate the manufacturing industry in 2022. 3D Printing Numerous industries, including aerospace, healthcare, electronics, and architecture, utilize 3D printing in manufacturing. It is the most widely used technology across industries and will remain so in 2022 and in the years to come. We may also anticipate more advancements in this technology to help overcome current barriers to 3D printing adoption, including equipment costs, material constraints, lengthier manufacturing times, a lack of knowledge, and legal issues. Additionally, it would assist manufacturers in overcoming current manufacturing challenges such as increasing product demand, increasing automation, and locating and retaining the workforce in manufacturing plants. It is vital to incorporate 3D technology into production processes to achieve greater precision and accuracy in manufacturing. IoT The Internet of Things is a critical component of the industry 4.0 revolution. It has altered the environment of data collection and analysis across sectors. For example, the Internet of Things is assisting manufacturers in better understanding manufacturing and supply chain operations, forecasting product demand, and boosting customer experiences. Implementing IoT in your manufacturing plant will also help you avoid production delays and increase the performance of your production lines. Additionally, it will decrease equipment downtime and improve process efficiency. It also enhances worker safety and enables more effective labor management. To begin implementing IoT in your manufacturing plant, you must first examine your manufacturing processes and research how other organizations have implemented IoT in their manufacturing processes or products. This method will assist you in determining the optimal location to begin integrating the IoT in your manufacturing plants and transforming them into smart ones. “Once you start to look at yourself in the right way and realize that projects are at the core of your business, it is easy to see how you should use technology to support your business.” – Matt Mong, VP of Market Innovation and Project Business Evangelist at Adeaca. GD & T The model created in the CAD program for any product is not exactly replicated with the exact dimensions during the production procedures. Thus, manufacturers or engineers utilize GD&T (Geometric Dimension &Tolerancing) to manage and communicate the permissible variation within a product assembly to manufacturing partners and inspectors. GD&T is a programming language that enables developers and inspectors to optimize functionality without incurring additional costs. The primary advantage of GD&T is that it expresses the design intent rather than the final geometry. However, as with a vector or formula, it is a representation of the actual item. AR & VR The two primary transformation aspects in the industry 4.0notion are augmented reality (AR) and virtual reality (VR). AR technology in manufacturing enables firms to operate more efficiently by reducing production time. Additionally, it discovers and resolves manufacturing process difficulties. Virtual reality technology benefits the industrial business in a variety of ways. It enables product designers to mimic their prototypes or models using powerful virtual reality software. This enables them to correct faults at the first stage of production and minimize production time and cost. Additionally, the technology provides additional benefits, such as increased workplace productivity and safety. ERP Enterprise Resource Planning (ERP) refers to a comprehensive end-to-end software solution that is used across sectors. It assists the manufacturing business in successfully maintaining production processes and other operational data by avoiding numerous roadblocks along the way. ERP technology enables enterprises to improve process efficiency and product quality by tackling industry-specific difficulties such as insufficient data, operation integration, inventory control, supply chain management, and on-time delivery. Discover How John Deere Manufactured Their Tractors Using Cutting-edge Technologies John Deere is a significant firm that embraces innovation and the Internet of Things. The company integrates Internet of Things sensors, wireless communication, and intelligent land management systems. It further integrates IoT tools into its manufacturing process, bridging the gap between technologies. Additionally, the company is a pioneer in GPS technology. Its most modern technology, which it incorporates into tractors, is accurate to within two centimeters. Additionally, the organization has implemented telemetry technology for predictive maintenance. Final Words Manufacturing innovations are assisting manufacturers in modernizing their traditional manufacturing processes. Modern manufacturing is equipped with modern technologies that aim to improve the processes and goods, increasing the manufacturers' commercial revenues. So, to remain competitive in this age of technological innovation, manufacturers must update their manufacturing processes to remain relevant in today's manufacturing world. FAQ What is manufacturing innovation? Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors. Which technologies are considered to be a component of advanced manufacturing? 3–D printing, robotics, IoT, nanotechnology, cloud computing, robotics, and big data are the significant components of advanced manufacturing. How are cutting-edge technologies assisting the manufacturing sector? The cutting-edge technology can precisely estimate demand to set production objectives, analyze machine data to predict when parts will break before a human operator can detect, and more. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What is manufacturing innovation?", "acceptedAnswer": { "@type": "Answer", "text": "Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors." } },{ "@type": "Question", "name": "Which technologies are considered to be a component of advanced manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "3–D printing, robotics, IoT, nanotechnology, cloud computing, robotics, and big data are the significant components of advanced manufacturing." } },{ "@type": "Question", "name": "How are cutting-edge technologies assisting the manufacturing sector?", "acceptedAnswer": { "@type": "Answer", "text": "The cutting-edge technology can precisely estimate demand to set production objectives, analyze machine data to predict when parts will break before a human operator can detect, and more." } }] }

Read More

Considering ERP in Manufacturing? Determine ROI

Article | April 21, 2022

Manufacturing ERP (enterprise resource planning) benefits organizations in multiple ways, as it simplifies decision-making for top management by utilizing data from smart dashboards and consolidated data. The requirements of manufacturing companies are extremely precise. These include elements like planning and management. Manufacturing ERP systems are designed to meet these requirements. In other words, manufacturing ERP is a specialized form of an ERP system designed to streamline and automate all manufacturing processes. It applies the same ERP principles to manufacturing organizations to increase efficiency. Numerous businesses have implemented or are planning to implement ERP systems in their manufacturing organizations. They are, however, constantly on the lookout for the best return on investment when it comes to manufacturing ERP software. In this article, we'll look at how to calculate the return on investment for manufacturing ERP solutions to help you get a better grasp of the investment viewpoint for manufacturing ERP. How to Determine Manufacturing ERP ROI? Organize Data for ROI ERP evaluation, selection, and implementation require collecting a large amount of business data. Putting all of this information together can be a daunting task. Therefore, individuals from each department should provide objective feedback to help mitigate bias and ensure consistency. Focus on People and Processes Rather than Technology You can increase your ROI by mitigating the technical aspects of an ERP system. Get an understanding of how it will improve your processes and how much money you will save over time due to those improvements. Your return on investment will depend on how well you effectively manage business process reengineering and organizational change. Invest Time and Effort in Your ERP Deployment It is critical to set realistic expectations and forecast the ROI benefits. Estimate the project's time, cost, and effort by consulting an expert, preferably not the ERP vendor, as their estimates may not be entirely accurate for their benefit. Predicting ERP Cost Costs associated with ERP, such as licenses and hardware, are easily quantifiable. Apart from these fees, additional expenses must be addressed and evaluated. They include subscription fees for SaaS, consulting, maintenance, and user fees. Consider the following questions: How you will implement your solution: Cloud or On-Premise? How many users are required? What equipment do you require to operate your business? What implementation and training requirements do you have? Calculating these expenditures may take considerable time. Mentioned below is the list of costs that can be estimated prior to investing: Out-of-the-box System Price Many business owners believe that this ERP cost is straightforward to determine because it is based on the vendor's quote. That, however, depends upon the modules and deployment options required in your business. License Fees – on Premise Vs. SAAS On-premise ERP software runs on your company's servers. This incurs a one-time license charge. On-premise deployments need organizations to maintain their servers to assure software functionality both in the present and future. It is therefore important to factor in these costs. Licenses are “repurchased” every five years, which is another cost to consider. Cloud ERP SaaS is hosted remotely on a third-party server and is accessible online. You must pay a monthly subscription fee until you stop using the system. Updates to the ERP system are free. Consultancy Costs and Vendor Implementation Fees A consultant's price must be considered if you hire one. To minimize future troubles and costs, it is vital to identify the actions and timeframes they will accomplish. ERP consultants provide implementation services such as data migration, project management, and system customization. Some consultants charge extra for these services, so be careful to ask how their pricing operates. Maintenance Cost Your servers and machines should meet the vendor's minimal requirements. You may need to update your equipment to support the ERP deployment, which will affect your ROI calculations. Maintenance expenses should include IT labor, extra server expenditures, and other departmental charges. Also, the ERP vendor may charge an annual maintenance fee to upgrade to new technology. User Cost Training your employees on the new ERP system is critical to its efficiency. Training takes time and money. It will depend on how many employees need to be trained, how difficult the processes are to learn, and whether you need to engage extra trainers or managers to help speed up new production processes. The budget should never be exceeded; otherwise, the ROI will suffer. Final Word A manufacturing ERP system is an integral part of any modern manufacturing organization. It helps your business in multiple ways to accelerate operations and business processes. Always conduct a thorough analysis of why you are looking out for ERP solutions and how they will help your businesses in becoming more productive than it is now. The ROI for manufacturing ERP is calculated by comparing the anticipated cost of ERP to the expected benefits (direct and indirect cost savings) of installing the ERP system. ROI is computed by adding the predicted ERP returns and dividing by the ERP TCO (Total Cost of Ownership); the resulting quotient is the ERP ROI. FAQ What is ERP used for in production? Manufacturing ERP is a centralized approach to managing production and payroll activities. ERP improves operational efficiency by providing unprecedented visibility, coordination, and management across a company's many activities. What are the types of ERP? There are three main types of ERP systems, each with varying deployment models. ERP systems can be cloud-based, on-premises, or hybrid. How long does it take for an ERP investment to pay off? A typical project can take between 12 and 24 months to complete, depending on the scope and complexity of the work.

Read More

Is Additive Manufacturing the Key to Restore American Manufacturing?

Article | November 20, 2021

Additive manufacturing in America plays a significant part in reviving the manufacturing industry and establishing the country as a leader in applying additive manufacturing technology. The United States was formerly the industrial leader, but it fell out of favor between 2000 and 2010 for many reasons, including recession and structural and financial instability. In this challenging time, technology interventions such as additive manufacturing in the manufacturing business have allowed the industry to survive. As per the recent report by A.T. Kearney, the USA, the industry leader in manufacturing, has worked hard to reclaim its top position in manufacturing and has also been named the leader in additive manufacturing. Let's look at which fields of America are utilizing the benefits of additive manufacturing technology to reclaim its position as the industry leader. Additive Manufacturing in America The manufacturing industry is gravitating toward additive manufacturing, sometimes known as 3D printing. The numerous advantages of additive manufacturing, such as the reduction of material waste, the reduction of prototyping time, the reduction of prototyping costs, the creation of lightweight objects, and the ease with which it can be implemented and recreated, are making it more popular around the world, including in the United States. In the United States, the additive manufacturing and material industry is expected to be worth $4.1 billion by 2020. China is the world's second-largest economy and is expected to reach a projected market size of US$14.5 billion by 2027, with a CAGR of 27.2 percent from 2020 to 2027. How does America Leverage the Additive Manufacturing? US Airforce has launched research into 3D printing The US Air Force has begun researching 3D printing replacement parts for old planes utilizing a 3D printing platform. The project initiative credit goes to 3D Systems, Lockheed Martin, Orbital ATK, and Northrop Grumman. America Makes will observe the project in its third stage and be led by the University of Dayton Research. The Air Force Laboratory financed the Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS) program. The US Air Force will investigate how the 3D printing technology may reproduce components for outdated aircraft. Using additive manufacturing, the replacement parts may be created faster and in smaller batches, with no minimum order quantity. In addition, applying additive manufacturing will reduce the aircraft ground time and eliminate the need for parts warehousing. American Manufacturing Companies and Additive Manufacturing 3D Systems, Inc. 3D Systems is an additive manufacturing company. Their work goes beyond prototyping. The company's experts use their deep domain expertise in aerospace and healthcare industries to produce competitive additive manufacturing solutions. This global leader in additive manufacturing helps you define business needs, verify manufacturing flow, and scale manufacturing flow. General Electric GE has seen the benefits of additive manufacturing and its options for product design, such as the potential to build lighter, more vital components and systems. As a result, they created goods that are better performing, more sophisticated in design, and easier to produce. Ford Ford's advanced manufacturing center in Michigan is all about additive manufacturing. The company employs 3D printing extensively in product development and is looking to integrate it into manufacturing lines. As a result, additive manufacturing is now a critical aspect of the Ford product development cycle, enabling prototype parts and product engineering exercises. Final Words The American manufacturing industry has experienced a renaissance as a result of the advent of additive manufacturing. Additionally, it has built its national accelerator and leading collaborative partner in additive manufacturing, "America Makes," which is the largest manufacturing industryglobally in terms of revenue and operates in a variety of areas. However, it is mainly focused on 3D printing or additive manufacturing, which is undoubtedly reviving the country's manufacturing sector. FAQ What are the significant challenges in additive manufacturing? Limitations in terms of size, consistency of quality, scalability, a limited variety of materials and high material costs, and limited multi-material capabilities are only a few of the prevalent issues associated with additive manufacturing technology. Which company is leading in additive manufacturing technology in the USA? 3D Systems Corp. is the leading company in additive manufacturing technology with a revenue of $566.6 million. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What are the significant challenges in additive manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Limitations in terms of size, consistency of quality, scalability, a limited variety of materials and high material costs, and limited multi-material capabilities are only a few of the prevalent issues associated with additive manufacturing technology." } },{ "@type": "Question", "name": "Which company is leading in additive manufacturing technology in the USA?", "acceptedAnswer": { "@type": "Answer", "text": "3D Systems Corp. is the leading company in additive manufacturing technology with a revenue of $566.6 million." } }] }

Read More

Manufacturing in 2022 - Five Emerging Trends in the Industry

Article | October 8, 2021

The trends in the manufacturing industry for 2022 are expanding and altering the industry's conventional face. The future of manufacturing is going to merge with digitalization and technological applications. As a result, all operation methods, products, and manufacturing outcomes will be modernized with new technology applications. To brighten the future of manufacturing, manufacturing companies must examine new trends in the industry before developing their manufacturing plans for 2022. Technological advancements are the next game-changer in the manufacturing business. Adeaca's Vice President of Market Innovation and Project Business Evangelist had recently quoted in an interview with Media7 as, “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 The new trends in manufacturing are leveling up every part and element of the industry. In this article, we'll look at a new trend for each industry aspect that's assisting manufacturers in speeding up the production process, increasing ROI, and propelling their manufacturing business to new heights. Additionally, it will assist you in addressing current industry challenges such as forecasting product demand, addressing skilled manpower shortages, and increasing manufacturing plant efficiency. Five Manufacturing Industry Trends to Watch in 2022 Emerging trends in manufacturing provide a chance to review your production strategy for products and processes. Check out below the upcoming trends in manufacturing that are getting attention in the industry. Customer Engagement and Purchase Experience Creating an exceptional digital customer experience is a new trend in manufacturing. According to industry experts, mapping the customer journey and their interactions with your products is the first step towards establishing a positive connection with your potential consumers. A few of the most popular strategies to improve the consumer purchasing experience and engagement are as follows: Build a knowledge base for your products on your business website Create a comprehensive FAQs page that addresses all of the buyer's possible queries Create a chatbot to provide immediate help to the buyer with further inquiries Create a brand story and a comprehensive description of your manufacturing business If possible, provide product statistics and success stories, and content about consumer satisfaction with your product Create a product functionality video or explanatory picture material to familiarize the potential customer with your product These are some of the trends that engage your prospective buyers and increase their purchasing experience through a range of product-related information and educate them about you and your products. Smart Technology-enabled Products Smart is the new norm in every industry. The old operations and goods that were once a part of everyone's life have now been replaced by technology. Manufacturing is no exception to this alteration. Due to the increasing demand for smart products among customers, every company is now looking forward to inventing and manufacturing smart products. Explore and understand how you may incorporate cutting-edge technology (Artificial Intelligence, Machine Learning, Edge Computing, and Digital Twins, and more) into your products to help them stay updated with manufacturing trends. Virtual and Augmented Reality in Manufacturing (Industry 4.0) Transforming traditional manufacturing systems and processes into smart, tech-savvy ones is a new trend in manufacturing. The future of manufacturing is expected to witness this digitization in 2022 and beyond. Therefore, you must convert your conventional manufacturing plants into smart ones, i.e., as per the concept of Industry 4.0 – the fourth industrial revolution. Discover how prominent companies are implementing Industry 4.0 The following are some popular transformations that many popular manufacturing factories are adopting to become part of the industry revolution. To achieve a zero-carbon footprint, manufacturers may use analytics systems to determine the amount of trash they create and develop ways to eliminate it. (Implemented by Whirlpool) Utilize an analytics platform to decipher usage data for energy, water, and other utilities. (Implemented by Whirlpool) Utilize technology such as Siemens' Mindsphere, which enables online analysis of several aspects of a production plant and helps manufacturers create digital models using real-time data. (Implemented by Siemens) Utilize a combination of IoT and cloud-based technologies to avoid downtime and gather analytics data. (Implemented by Hirotec – a Japan based manufacturing company) Machine learning technology can be used to foretell and avoid system failures in your manufacturing plant. (Implemented by Hirotec – a Japan based manufacturing company) Utilize robotics and to accelerate manufacturing across many verticals. (Implemented by Ford) Utilize 3D printing to improve the precision of product design and to avert product defects during the early production stage. (Implemented by Aerospace: Airbus) These are some examples that other well-known manufacturing companies in the market, such as Hewlett-Packard, Ford, Whirlpool, and Siemens are currently using. So, consult an expert and determine how to leverage emerging technology to turn your production plant into a smart manufacturing unit. Internet of Things (IoT) to Boost Revenue Manufacturing companies have begun to leverage the Internet of Things to establish connectivity between machines and operational procedures throughout manufacturing. This linkage between machine and operation significantly decreases the human supervision required for each step and completely automates them. Manufacturers intend to incorporate these IoT trends in manufacturing into both their products and operational processes. IoT further enables manufacturers to operate and monitor their work remotely. As a result, they can concentrate on developing new strategies and preparing for future ventures. Shifting Focus from B2B to B2C Model Several manufacturers skip intermediaries and connect directly with their consumers to sell efficiently to their target consumer group. This purposeful approach has multiple benefits, which are outlined below. Manufacturers may skip the lengthy retail sales cycle and achieve a shorter time to market The absence of a third party between the manufacturer and the customer reduces the risk of brand misinterpretation or dilution Direct interaction with customers enables manufacturers to obtain more accurate consumer data, product feedback, and requirements for new product development Manufacturers can control the price of their products due to the absence of a third party between them and the target consumer group These benefits of the B2C model attract manufacturers and encourage them to develop added production techniques with these benefits in mind. Final Words Technology, innovation, and digitization are the future of manufacturing. The IoT trends in manufacturing are essential for industrial production and will allow the manufacturing industry to obtain a new competitive edge. Hence, manufacturers must keep in mind this industry revolution (industry 4.0 and 5.0) while developing strategies for their manufacturing operations in 2022. FAQs What are the benefits of adopting the Internet of Things in manufacturing? IoT devices can monitor industrial operations, manufacturing cycles, and other warehouse data management processes automatically. This benefit decreases the amount of time spent monitoring individual operations and increases production speed. What role will smart manufacturing play in the future? According to a grand view research analysis, the smart manufacturing market was worth USD 236.12 billion in 2020 and is expected to extend at a 12.4 percent compound annual growth rate to reach USD 589.98 billion by 2028. What are the critical components of the smart factory of the future? Robotics, the Internet of Things, big data, and cloud-based administration will be critical components of the future smart factory.

Read More

Technologies That Will Keep You Ahead in the Manufacturing Realm

Article | November 20, 2021

Modern manufacturing methods are pioneering and adopting manufacturing industry advancements. To remain competitive in the present era and provide the most excellent industry solutions to your organization and target customer group in 2022, you must employ new manufacturing technologies in your manufacturing processes. Additionally, embracing current technologies is the ideal approach to tackle the industry's current challenges such as workplace safety, digitalization of operations, and a lack of skilled workers. This article will discuss some of the leading manufacturing technologies that transform traditional manufacturing facilities into smart manufacturing factories. So, let us begin. Manufacturing Technology & Innovations for 2022 To better understand industry 4.0, let's look at some of the manufacturing technologies that will dominate the manufacturing industry in 2022. 3D Printing Numerous industries, including aerospace, healthcare, electronics, and architecture, utilize 3D printing in manufacturing. It is the most widely used technology across industries and will remain so in 2022 and in the years to come. We may also anticipate more advancements in this technology to help overcome current barriers to 3D printing adoption, including equipment costs, material constraints, lengthier manufacturing times, a lack of knowledge, and legal issues. Additionally, it would assist manufacturers in overcoming current manufacturing challenges such as increasing product demand, increasing automation, and locating and retaining the workforce in manufacturing plants. It is vital to incorporate 3D technology into production processes to achieve greater precision and accuracy in manufacturing. IoT The Internet of Things is a critical component of the industry 4.0 revolution. It has altered the environment of data collection and analysis across sectors. For example, the Internet of Things is assisting manufacturers in better understanding manufacturing and supply chain operations, forecasting product demand, and boosting customer experiences. Implementing IoT in your manufacturing plant will also help you avoid production delays and increase the performance of your production lines. Additionally, it will decrease equipment downtime and improve process efficiency. It also enhances worker safety and enables more effective labor management. To begin implementing IoT in your manufacturing plant, you must first examine your manufacturing processes and research how other organizations have implemented IoT in their manufacturing processes or products. This method will assist you in determining the optimal location to begin integrating the IoT in your manufacturing plants and transforming them into smart ones. “Once you start to look at yourself in the right way and realize that projects are at the core of your business, it is easy to see how you should use technology to support your business.” – Matt Mong, VP of Market Innovation and Project Business Evangelist at Adeaca. GD & T The model created in the CAD program for any product is not exactly replicated with the exact dimensions during the production procedures. Thus, manufacturers or engineers utilize GD&T (Geometric Dimension &Tolerancing) to manage and communicate the permissible variation within a product assembly to manufacturing partners and inspectors. GD&T is a programming language that enables developers and inspectors to optimize functionality without incurring additional costs. The primary advantage of GD&T is that it expresses the design intent rather than the final geometry. However, as with a vector or formula, it is a representation of the actual item. AR & VR The two primary transformation aspects in the industry 4.0notion are augmented reality (AR) and virtual reality (VR). AR technology in manufacturing enables firms to operate more efficiently by reducing production time. Additionally, it discovers and resolves manufacturing process difficulties. Virtual reality technology benefits the industrial business in a variety of ways. It enables product designers to mimic their prototypes or models using powerful virtual reality software. This enables them to correct faults at the first stage of production and minimize production time and cost. Additionally, the technology provides additional benefits, such as increased workplace productivity and safety. ERP Enterprise Resource Planning (ERP) refers to a comprehensive end-to-end software solution that is used across sectors. It assists the manufacturing business in successfully maintaining production processes and other operational data by avoiding numerous roadblocks along the way. ERP technology enables enterprises to improve process efficiency and product quality by tackling industry-specific difficulties such as insufficient data, operation integration, inventory control, supply chain management, and on-time delivery. Discover How John Deere Manufactured Their Tractors Using Cutting-edge Technologies John Deere is a significant firm that embraces innovation and the Internet of Things. The company integrates Internet of Things sensors, wireless communication, and intelligent land management systems. It further integrates IoT tools into its manufacturing process, bridging the gap between technologies. Additionally, the company is a pioneer in GPS technology. Its most modern technology, which it incorporates into tractors, is accurate to within two centimeters. Additionally, the organization has implemented telemetry technology for predictive maintenance. Final Words Manufacturing innovations are assisting manufacturers in modernizing their traditional manufacturing processes. Modern manufacturing is equipped with modern technologies that aim to improve the processes and goods, increasing the manufacturers' commercial revenues. So, to remain competitive in this age of technological innovation, manufacturers must update their manufacturing processes to remain relevant in today's manufacturing world. FAQ What is manufacturing innovation? Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors. Which technologies are considered to be a component of advanced manufacturing? 3–D printing, robotics, IoT, nanotechnology, cloud computing, robotics, and big data are the significant components of advanced manufacturing. How are cutting-edge technologies assisting the manufacturing sector? The cutting-edge technology can precisely estimate demand to set production objectives, analyze machine data to predict when parts will break before a human operator can detect, and more. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What is manufacturing innovation?", "acceptedAnswer": { "@type": "Answer", "text": "Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors." } },{ "@type": "Question", "name": "Which technologies are considered to be a component of advanced manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "3–D printing, robotics, IoT, nanotechnology, cloud computing, robotics, and big data are the significant components of advanced manufacturing." } },{ "@type": "Question", "name": "How are cutting-edge technologies assisting the manufacturing sector?", "acceptedAnswer": { "@type": "Answer", "text": "The cutting-edge technology can precisely estimate demand to set production objectives, analyze machine data to predict when parts will break before a human operator can detect, and more." } }] }

Read More

Considering ERP in Manufacturing? Determine ROI

Article | April 21, 2022

Manufacturing ERP (enterprise resource planning) benefits organizations in multiple ways, as it simplifies decision-making for top management by utilizing data from smart dashboards and consolidated data. The requirements of manufacturing companies are extremely precise. These include elements like planning and management. Manufacturing ERP systems are designed to meet these requirements. In other words, manufacturing ERP is a specialized form of an ERP system designed to streamline and automate all manufacturing processes. It applies the same ERP principles to manufacturing organizations to increase efficiency. Numerous businesses have implemented or are planning to implement ERP systems in their manufacturing organizations. They are, however, constantly on the lookout for the best return on investment when it comes to manufacturing ERP software. In this article, we'll look at how to calculate the return on investment for manufacturing ERP solutions to help you get a better grasp of the investment viewpoint for manufacturing ERP. How to Determine Manufacturing ERP ROI? Organize Data for ROI ERP evaluation, selection, and implementation require collecting a large amount of business data. Putting all of this information together can be a daunting task. Therefore, individuals from each department should provide objective feedback to help mitigate bias and ensure consistency. Focus on People and Processes Rather than Technology You can increase your ROI by mitigating the technical aspects of an ERP system. Get an understanding of how it will improve your processes and how much money you will save over time due to those improvements. Your return on investment will depend on how well you effectively manage business process reengineering and organizational change. Invest Time and Effort in Your ERP Deployment It is critical to set realistic expectations and forecast the ROI benefits. Estimate the project's time, cost, and effort by consulting an expert, preferably not the ERP vendor, as their estimates may not be entirely accurate for their benefit. Predicting ERP Cost Costs associated with ERP, such as licenses and hardware, are easily quantifiable. Apart from these fees, additional expenses must be addressed and evaluated. They include subscription fees for SaaS, consulting, maintenance, and user fees. Consider the following questions: How you will implement your solution: Cloud or On-Premise? How many users are required? What equipment do you require to operate your business? What implementation and training requirements do you have? Calculating these expenditures may take considerable time. Mentioned below is the list of costs that can be estimated prior to investing: Out-of-the-box System Price Many business owners believe that this ERP cost is straightforward to determine because it is based on the vendor's quote. That, however, depends upon the modules and deployment options required in your business. License Fees – on Premise Vs. SAAS On-premise ERP software runs on your company's servers. This incurs a one-time license charge. On-premise deployments need organizations to maintain their servers to assure software functionality both in the present and future. It is therefore important to factor in these costs. Licenses are “repurchased” every five years, which is another cost to consider. Cloud ERP SaaS is hosted remotely on a third-party server and is accessible online. You must pay a monthly subscription fee until you stop using the system. Updates to the ERP system are free. Consultancy Costs and Vendor Implementation Fees A consultant's price must be considered if you hire one. To minimize future troubles and costs, it is vital to identify the actions and timeframes they will accomplish. ERP consultants provide implementation services such as data migration, project management, and system customization. Some consultants charge extra for these services, so be careful to ask how their pricing operates. Maintenance Cost Your servers and machines should meet the vendor's minimal requirements. You may need to update your equipment to support the ERP deployment, which will affect your ROI calculations. Maintenance expenses should include IT labor, extra server expenditures, and other departmental charges. Also, the ERP vendor may charge an annual maintenance fee to upgrade to new technology. User Cost Training your employees on the new ERP system is critical to its efficiency. Training takes time and money. It will depend on how many employees need to be trained, how difficult the processes are to learn, and whether you need to engage extra trainers or managers to help speed up new production processes. The budget should never be exceeded; otherwise, the ROI will suffer. Final Word A manufacturing ERP system is an integral part of any modern manufacturing organization. It helps your business in multiple ways to accelerate operations and business processes. Always conduct a thorough analysis of why you are looking out for ERP solutions and how they will help your businesses in becoming more productive than it is now. The ROI for manufacturing ERP is calculated by comparing the anticipated cost of ERP to the expected benefits (direct and indirect cost savings) of installing the ERP system. ROI is computed by adding the predicted ERP returns and dividing by the ERP TCO (Total Cost of Ownership); the resulting quotient is the ERP ROI. FAQ What is ERP used for in production? Manufacturing ERP is a centralized approach to managing production and payroll activities. ERP improves operational efficiency by providing unprecedented visibility, coordination, and management across a company's many activities. What are the types of ERP? There are three main types of ERP systems, each with varying deployment models. ERP systems can be cloud-based, on-premises, or hybrid. How long does it take for an ERP investment to pay off? A typical project can take between 12 and 24 months to complete, depending on the scope and complexity of the work.

Read More
MORE ARTICLE

Spotlight

Tesmec

Tesmec Group is leader in designing, manufacturing and selling of systems, technologies and integrated solutions for the construction, maintenance and efficiency of infrastructures related to the transport and distribution of energy, data and material. STRINGING: designing, manufacturing and supplying machines and accessories for stringing operations and equipment for the construction and maintenance of infrastructures for energy transport and distribution.

Events