3 Ways to Improve Efficiency in your Production Line

Production lines are installed in industrial manufacturing to increase production and efficiency. But what happens when those lines begin to slow, waste money, energy and ultimately affect a company’s bottom line?  

It’s important to be aware of signs a production line is being inefficient, and how to improve performance.

Read on to learn more about ways to improve efficiency in your own production line.  

RECONDITION YOUR EQUIPMENT  

Production lines rely on manufacturing equipment and industrial robots to be in prime condition in order to keep processes as efficient as possible. Over time, even new machines purchased will begin to show wear and tear, and it’s important to know the signs to spot when it’s time to give your equipment new life.  

Routine maintenance is key to staying on top of repairs or cleaning that might need to happen in order to keep your industrial robot or machine running like new. Finding a balance between regular updates and downtime is important when evaluating the maintenance schedule. If more repairs and upkeep are required over time, it may be an opportunity for reconditioning your equipment. Reconditioning extends the life of machinery and can involve something as simple as a deep clean, removing dust, grease, and other items, or replacing old parts.  

NRTC Automation offers two levels of reconditioning services, which are tailored to your individual requirements, as well as offering industrial robot painting services and repairs.  

EMPLOYEE TRAINING  

Although manufacturing automation depends largely on robotics and machinery, the employees of a business, especially a production facility, are just as, if not more, important than the production line itself.  

Employees need to stay engaged and informed, with regular meetings and cross-training. A regular meeting schedule with staff can not only keep employees abreast of any future changes or updates, but also keeps a line of communication open for employees to express problems on the floor or with current machinery or industrial robots. 

Additional training, such as cross-training, allows for a wider net of safety and information to be cast over a production facility. If an employee can understand the entire production process, they are then able to assist others in different roles if needed or to fill production gaps. 

NRTC provides robotic training services for industrial manufacturers and production facilities, allowing for employees to keep up-to-date on new information, technology, and processes. 

UPGRADING SYSTEMS  

If an industrial robot is passed the point of being able to be reconditioned, it is worth it to look into replacing the machinery. Often times, replacing a system can be more cost-effective in the long run than continually repairing and reconditioning it.  

Purchasing a newer, but still used, high-quality machine or robot is a price-saving practice that can still upgrade production without breaking a budget. Our sister company iGAM has multiple options for high-end used industrial machines and robots.  

Additionally, implementing lean manufacturing processes that create less waste can improve production efficiency, save costs, and of course, positively impact the environment. NRTC Automation specialized in designing, engineering and building custom, turnkey robotic work cells that can increase productivity and efficiency in your production line.  

NRTC CAN HELP

NRTC Automation helps manufacturers of all sizes with automation, training, and robotic solutions to fit every need and keep production efficient. We offer custom turnkey weld cells, engineering contract services, and more. To learn additional information, or to contact our team, visit us here.  

5 Methods for a Lean Manufacturing Process

Lean is the way of the future. Get on top of your production waste by trying out one or more of these lean manufacturing methods. 

Manufacturing continues to change with technology and new ideas, and so manufacturers need to stay abreast of these innovations to remain competitive in their industry. 

Lean manufacturing is one of the most important developments in manufacturing history, and it continues to inspire big-name manufacturers like Toyota today. 

To start going lean and improve your production processes, learn more about the history of lean and popular methods below. 

Using lean manufacturing methods

What is lean manufacturing? 

Lean manufacturing is a methodology that applies practices and principles to reduce waste, minimize downtime, increase cost savings, and produce sustainably. 

Although there is evidence of lean manufacturing methods back in the 15th century, the first real application of lean was in Henry Ford’s production line in 1913. In the 1930s and after World War II, Toyota led the world in lean manufacturing, providing monumental lean philosophies such as 5S. 

Since then, lean manufacturing has developed into innovative philosophies that have changed how we manufacture today. 

Benefits of going lean 

The reason why manufacturing companies continue to use lean methodology is because of the numerous benefits it provides. Some of these benefits include: 

• Reduced lead time: Efficient manufacturing reduces lead time, shipping your product out faster for higher customer satisfaction. 

• Improved product quality: Product quality is improved when wasted motions and materials are removed. Like Antoine de Saint-Exupery said, “Perfection is achieved, not when there is nothing more to add, but when there is nothing left to take away.” 

• Less product waste: As mentioned, lean manufacturing reduces product waste by removing unnecessary materials during the manufacturing process. 

• Minimal downtime: Less time is wasted during lean manufacturing since processes are more efficient. 

• Increased cost savings: Because product quality is improved, downtime is minimized, and fewer materials are wasted, manufacturers see an increase in cost savings when they go lean. 

• Sustainability: Lean manufacturing is far more sustainable than traditional manufacturing, which is a necessity for consumers who demand better from companies. 

To reap the benefits of lean thinking, learn five different methods of lean manufacturing below. 

5 methods for a lean manufacturing process 

1. KANBAN 

The purpose of Kanban is to manage workflow processes in a visual manner. Kanban is Japanese for “sign,” and it was developed by Toyota in the 1940s. 

In order to add Kanban thinking to your production line, start implementing visual cues of the progress of your products on the warehouse floor. This could be a digital board or a physical board that includes categories such as “Ready to Start,” “Working,” “Waiting,” “Review,” and “Done.” 

2. KAIZEN 

Kaizen is a form of Japanese business philosophy meaning “continuous improvement” or “change for the better." This lean method focuses on holistically improving product quality, company culture, and production efficiency. 

It is a cycle of progression that constantly analyses production inefficiencies to improve manufacturing. By tracking and measuring progress, manufacturers can create leaner production lines. 

3. CELLULAR MANUFACTURING 

Cellular manufacturing is applied to the layout of the manufacturing floor. It is the strategic arrangement of equipment and processes to reduce waste. 

Before cellular manufacturing, the flow of production was jumbled up, jumping around from one place to another throughout the plant. Now, manufacturers use cellular manufacturing to provide a seamless workflow through layouts such as the U-shape, straight line, or inverted U-shape. 

4. 3P 

The Ps of 3P stand for Production Preparation Process. By eliminating waste through prototyping, manufacturers can improve product quality and minimize downtime on the production floor. 

NRTC Automation provides prototyping services to help you create a leaner company. Reach out to us here to learn more about what we can do for you. 

5. 5S 

Last but not least, 5S is another popular method of lean. It stands for Sort, Set in Order, Shine, Standardize, and Sustain. This method of lean manufacturing also originated in Japan and centers efficiency around necessary versus unnecessary processes. 

It’s similar to adding key hooks near your front door so you don’t lose your car keys. By putting everything in its place, manufacturers can reduce downtime and improve productivity. 

Stay competitive in 2021 by getting leaner 

To stay competitive in your industry, start implementing more lean methodology into your manufacturing processes. Not only will you see an increase in cost savings and productivity, but you’ll have happier customers and greater demand for your product. 

OPTIMIZE YOUR PRODUCTION LINE WITH NRTC AUTOMATION 

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.  

From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services. 

Schedule a free consultation with NRTC to learn how we can free up time and resources on your production floor. 

3 Steps to Developing a Successful Production Line

Manufacturers can create more efficient and effective production lines with a little planning. 

Since the late 1800s, manufacturing has seen massive improvements in production. With little tweaks and modern technologies, manufacturers have been able to grow without bounds. 

Today, staying relevant in the industry means manufacturers must plan for the success of their production lines. Competition is fierce in a global market, and staying on top of trends is necessary to rise above the rest. 

Thankfully, you don’t have to go about it alone. With NRTC Automation’s resources, you can build a production line that serves you and your customers with quality and speed. 

Learn our three steps to developing a successful production line below. 

A successful production line is key to a successful business 

Your production line is the heart of your business. Why is that? 

It contains everything your business promotes to your customers: quality assurance, delivery speed, and plentiful supply. 

To keep those promises, you must ensure that your production line is highly refined and well-attended. 

That way, you will consistently provide your customers with: 

• Uniform, high quality, and durable products 

• Minimal lead time from customer order to date of shipment 

• A continuous supply to meet their demands 

However, just as CEOs have to plan and work to create a successful business, manufacturers must be strategic when developing their production lines. 

3 steps to developing a successful production line 

To meet the needs of your customers and continue to grow as a company, consider these three tips to enhance your production line. 

1. AUTOMATE, AUTOMATE, AUTOMATE 

Automation is the holy grail of manufacturing. Since the Industrial Revolution, manufacturers have been steadily automating processes to deliver their products faster. 

An example of this is when Henry Ford installed the first assembly line in 1913, effectively reducing production time for one car from 12 hours to one hour and 33 minutes! 

Since then, the manufacturing sector has seen vast improvements in production. Industrial robots were introduced in the mid-twentieth century and have advanced significantly since. Payloads are higher, applications are more flexible, arms and wrists are more refined, repeatability is more precise, and more. 

Automation is nothing new, and it is even more crucial now in 2021 as competition gets more intense and the global market introduces millions of potential customers. 

Add a KUKA industrial robot, FANUC robot, or ABB robot to your production line to keep up. If you are new to automation and need help getting started, NRTC Automation can design, build, and engineer a custom work cell for your company.  

Visit our Automation Services page to learn more about how we can help you improve throughput and capacity by over 200 percent. 

2. STAY ON TOP OF MAINTENANCE 

If you have already automated your production line, then staying on top of maintenance is absolutely necessary for the longevity of your equipment. 

Preventative maintenance will protect your equipment from breakdowns and part failures. Each piece of equipment will have a different maintenance schedule depending on the make and model, so be sure to keep equipment manuals in a central location to reference them when needed. 

What does machine maintenance usually consist of? 

• Routine checks 

• Replacing old or worn parts 

• Cleaning out old grease and replacing it with fresh grease 

• Replacing filters 

• Paint jobs 

• Replacing batteries 

Whether it is every three months or once a year, keeping up with your equipment maintenance schedules allows your equipment to work as efficiently as possible. Plus, regular maintenance will save you time and money on buying new equipment. 

Want to further extend the life of your industrial robots? Get Industrial Robot Refurbishing Services at NRTC Automation!

Plus, if you are in need of replacement parts, visit our sister company, iGAM. Their online marketplace is constantly growing with refurbished equipment and parts to complete your production line.

3. GET LEAN 

Last but not least, use lean manufacturing methodology to get your production line in the best shape possible. 

Lean methodology aims to reduce waste as much as possible to improve production efficiency. Think about it: the less waste that is produced during manufacturing, the less energy that is taken away from important production processes. 

There are plenty of methods to choose from—just choose the right method for your company’s manufacturing needs. Some examples include: 

• 5S 

• Cellular Manufacturing 

• 3P 

• Kaizen 

• Kanban 

• Six Sigma 

You can read the definitions of each of these methods on NRTC Automation’s glossary. 

Start using lean manufacturing methodology to further improve your production line and get ahead of the competition. 

Improve your bottom line today 

In manufacturing, efficiency is fundamental to success in today’s market. 

You’ve worked hard to get to where you are. Try out the tips we’ve listed above to get to where you want to be. 

WORK WITH NRTC AUTOMATION 

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.  

From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services. 

Schedule a free consultation with NRTC today to get the best automation plan for your company's specific needs. 

5 Common Costs in Manufacturing

Production can be expensive if it isn’t monitored. By paying attention to common manufacturing costs, you can increase your bottom line and grow your company. 

In manufacturing, cutting unnecessary costs through lean manufacturing methods is a sure-fire way to grow your company. 

There are a few production costs that you should keep an eye on in order to ensure that revenue is growing as much as possible. Check out our list below to find out what you should be looking for. 

5 common costs in manufacturing—and cost-saving solutions 

1. Labor 

A common cost in manufacturing is labor. Human labor consists of wages, taxes, payroll, benefits, and other costs such as occupational injuries. It also includes human mistakes, like defective products and wasted material.  

Many workers prefer creative and engaging work over tasks that are monotonous, highly repeatable, and require precision. Implementing automation in these tasks is the simplest way to save on labor costs while decreasing lead time and improving product quality. 

For example, in computer electronics manufacturing, human labor costs $24 an hour, whereas robot labor costs $4 an hour. If you want to cut labor costs and provide engaging and meaningful work for your employees, then consider adding industrial robots and equipment to your production line. 

NRTC Automation can build a custom robotic work cell specific to your company’s production needs. We use refurbished industrial robots for a cost-effective solution without compromising on quality. Plus, we offer financing and up to 1-year warranty coverage to give you peace of mind with your purchase. 

Additionally, we can find qualified manufacturing experts for your company at competitive prices. We will screen applicants to find a professional with experience that meets the need of your job. Visit our Engineering Services page to learn more. 

2. Energy 

Energy is another common cost that manufacturers must account for during production. 

Overhead can be pricy, especially if you aren’t using lean manufacturing practices. Using power factor correction equipment will help keep your energy costs low by managing the amount of energy that is used by your equipment during production. 

Other lean manufacturing practices include cutting out unnecessary steps in the production process to reduce lead time and cut energy costs. 

3. Quality control 

Lacking quality control is a huge cost in manufacturing. When a product is defective, throwing it away can be a nuisance. However, when a defect isn’t caught and the product is sent to customers, the recall can cost millions of dollars. 

Taking the time to develop a comprehensive quality control management system will save both face and recall costs. Standardizing this process will also reduce lead time, allowing you to take on more demand. 

4. Repairs 

Equipment breakdowns can be expensive. Not only do you have to pay for repairs, but unplanned downtime can have a disastrous effect on your bottom line. The average cost of downtime is $5,600 per minute, which can quickly escalate into hundreds of thousands of dollars in lost revenue. 

There are several ways you can avoid unplanned downtime. 

• Have a technician onsite: With an onsite technician, you can handle emergency repairs as they occur to minimize downtime. If you are looking for a technician but can’t find the right person for the job, consider using NRTC Automation’s Engineering Services. We’ll interview and hire professionals with the right experience to get the job done. 

• Stick to equipment maintenance schedules: One way to avoid repairs is by keeping up with equipment maintenance. For example, industrial robots should be maintained on a regular schedule depending on their working hours and manufacturer. By testing the robot, cleaning out grease, and replacing parts as needed, you can avoid costly repairs or equipment replacements. 

• Recondition equipment: Another way to avoid having to pay for repairs is by reconditioning your equipment. This will extend the life of your equipment. NRTC Automation offers several levels of reconditioning for industrial robots and equipment. 

5. Space 

Warehousing space is pricy. In manufacturing, the average rent paid per square foot was $6.36 in 2019. That can add up quickly, especially if you are looking to decommission your current warehouse and expand in the early stages of growth. 

Making the most out of your current warehouse space is the best way to save on space. Consider storing unused tools and equipment elsewhere to remove clutter from your warehouse and focus on operations as opposed to storage. If you are looking for a place to keep your equipment, NRTC Automation offers storage solutions for your industrial tools, fixtures, and equipment. 

You can also make use of the vertical space in your warehouse. If you have room to fit a second level, consider adding steel platforms and other access structures to create a second floor. This will double your working space in the warehouse and allow you to increase production. 

Grow your company by focusing on cost savings 

Keep track of costs associated with the list above to prune and adjust your production process for greater cost savings.  

Whether you are adding automation to your production line or saving space in the warehouse, NRTC Automation can help. Schedule a free consultation with us to learn more about how we can help you cut your production costs. 

PARTNER WITH NRTC AUTOMATION 

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.  

From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services. 

5 Reasons Your Production Line Is Inefficient

Production inefficiency can break an otherwise successful company by accumulating waste and expenses. 

Manufacturers of all industries, sizes, and phases can benefit from productivity analysis. This is especially true within production lines, where waste in the form of energy, materials, and money can negatively affect a company’s revenue. 

Understanding production inefficiency, and how to reach peak production efficiency, will help manufacturers to remain competitive in their fields. 

Learn more about how to fix production inefficiency in your manufacturing business below. 

How to fix production inefficiency 

What is production inefficiency? 

To explain production inefficiency, let’s start with production efficiency. 

Peak production efficiency, or productive efficiency, is when a company is producing the maximum amount of one good without wasting resources or lowering the production level of another good.  

Production inefficiency is when resources are wasted, or when production levels are lower than their potential. 

Production efficiency looks different for every company. However, each company can use similar guidelines to improve their production processes. 

Causes of inefficient production lines 

Determining the cause of production inefficiencies can be a complex job depending on the size and intricacy of the company’s manufacturing processes. 

Examine your factory for these common causes of inefficient production lines and see where you can make changes for more productive operations. 

1. MACHINE QUALITY AND PERFORMANCE 

Industrial robots and manufacturing equipment need to be in prime condition to work as efficiently as possible. 

Keeping a strict maintenance schedule is the easiest way to maintain machine quality and performance. If you notice that your equipment is beginning to slow down or use more energy than necessary, then consider sending it in for reconditioning. Reconditioning your equipment will extend its life by replacing old parts and cleaning out grease, dust, and other particles.  

You can also replace equipment if it is more cost-effective than reconditioning and repairing it. Consider buying quality-tested used industrial robots and equipment with reconditioning treatment for the biggest bang for your buck. 

2. EMPLOYEE KNOWLEDGE AND PERFORMANCE 

Your employees can make a huge difference in the productivity levels of your business. 

Educated employees who feel connected to their jobs and feel like a necessary part of the business are more likely to feel motivated to perform at their best and improve their work environment. 

We have a blog post on how to build a strong production team and why it matters for the health of your company. You can read that here. 

If you want to educate your staff in robotics for more capable and independent employees, take a look at NRTC Automation’s Robotic Training Services. We can personalize a plan for your company’s needs and give your employees the confidence to solve technical issues on their own. 

We also offer Robotic Engineering Services for companies who need to hire qualified and experienced technicians. Visit our website for more information. 

3. PRODUCT QUALITY 

Poor product quality can make your production line inefficient. Using low-quality raw materials will not only create more waste, but they can create products that do not meet product standards that must be thrown away.  

Even worse, low-quality end products can lead to customer dissatisfaction, which can destroy your company’s reputation. 

Optimize product design with prototyping and use high-quality materials for the best end product. Doing so will lessen the chance of material waste and potential customer loss. An inexpensive way to prototype is with a 3D printer that can quickly produce parts and prototypes without waste. The upfront investment is well worth the cost-savings in product waste and customer retention. 

4. SCHEDULE GAPS 

Latent schedule gaps in your production process can cause production inefficiency when machines have the potential to work. Planned downtime has its benefits, such as reducing hourly usage and maintenance, but downtime in general can be costly for manufacturers. 

Downtime can cost up to $5,600 per minute. If you have production schedule gaps that can otherwise be utilized, make the necessary changes to save on major downtime costs and improve production efficiency. 

5. LACK OF SUSTAINABLE PROCESSES 

Finally, an unsustainable factory creates waste in every part of the production process. Using sustainable manufacturing methods not only benefits the environment, but it will also improve your production efficiency and result in significant cost savings over time. 

To get involved in sustainability, learn more about lean manufacturing practices such as kaizen or 5S. These methods can help you reduce waste and create a faster, more productive manufacturing line. 

NRTC Automation can help you create a more sustainable production process by designing, building, and engineering a custom robotic work cell with refurbished industrial equipment. A robotic work cell will improve production efficiency and result in long-term cost savings by providing your company with flexible production. 

Get competitive by improving production efficiency 

Staying diligent with productivity analysis will help your company continue to grow by preserving revenue and resources. Check your factory for the causes of production inefficiency listed above to improve your business. 

WORK WITH NRTC AUTOMATION TO GROW YOUR BUSINESS. 

NRTC Automation is a trusted partner providing comprehensive industrial automation and manufacturing services. After delivering our services to top automobile manufacturers across the world for more than a decade, NRTC Automation is the destination for tear out services and robotic solutions. 

We offer financing and free consultations to help manufacturers of all sizes and phases to grow their businesses. Visit us today to learn more at www.nrtcautomation.com.