Developing a Successful Production Line

Developing a successful production line isn’t difficult. All you need is a little planning and the right tools. 

In the past 200 years, manufacturing productivity has increased by leaps and bounds with advancements in technologies and automation, making the sky the limit when it comes to production design ideas.  

Manufacturers need to plan before implementing or upgrading a production line, and keep in mind elements that will not only serve the company but that will also favor the end product and user. 

Read on to discover the steps you should take in order to develop a successful production line.  

AUTOMATION IS KEY  

Automating is a key factor in implementing a successful production line. And it’s nothing new. Did you know Henry Ford installed the first assembly line in 1913? He was able to reduce the production time for one of his cars from 12 hours to an hour and a half.  

Not only does automation improve your manufacturing process, but it also increases revenue while cutting waste from production as well as overhead costs.  

NRTC Automation produces pre-engineered and customized work cells, that are the ultimate turnkey solution. Our work cells include specialized robotic systems that cover your manufacturing needs from top to bottom.  

Adding elements like robotic arms to your production line can increase productivity and improve product quality. Additionally, they keep costs low and reduce the risk factors in dangerous or demanding environments.  

DEVELOPING AND IMPLEMENTING A MAINTENANCE PLAN  

Ensuring a production line stays successful can hinge on its maintenance plan. Production lines consist of a variety of elements, and each one will have its own set of maintenance requirements. Developing and implementing a preventative maintenance plan will protect equipment from failing or breaking down.  

Starting with a predictive plan, and not a reactive approach, will ensure less downtime for your production line. A recent GE study found that only 24% of operators described their maintenance approach as “predictive” resulting in a 5.42% annual unplanned downtime vs 8.43% for those adopting a “reactive approach”.  

Routine maintenance should include replacing old or worn parts, cleaning out and changing old grease, replacing filters, refreshing paint jobs, and replacing batteries. Keeping maintenance tasks like these on a schedule allows your equipment to work as efficiently as possible, saving you downtime as well as money from purchasing new equipment.  

NRTC offers industrial refurbishment services, from basic evaluations to complete overhauls. We can help extend the life of your robots and production line and return their functionality to the highest caliber.   

LEAN MANUFACTURING METHODOLOGY  

Lean manufacturing is one of the most effective ways to make sure your production line is in the best shape possible. Keeping a lean methodology aims at reducing waste to improve the efficiency of production. Less waste equals less energy.  

There are many different methodologies you can implement, such as 3P, Six Sigma, and Kaizen. Learn more about these methods on the NRTC Automation glossary page.  

Start your Successful Production Line Today  

Efficiency is fundamental to success in today’s market, and NRTC Automation can help you get there. We are dedicated to providing industrial and manufacturing solutions to all of our customers, big or small. From automation solutions and turnkey weld cells, to robot refurbishing and engineering contract services, we have you covered.  

Contact us for a free quote and see how we can help you develop a successful production line.  

NRTC Celebrates Manufacturing Day

October 7th is Manufacturing Day, and here at NRTC Automation we are celebrating this holiday by reflecting on our involvement in the manufacturing industry. The holiday is held on the first Friday in October each year, and it allows the manufacturing community to come together to celebrate innovation, hard work, and education in our sector. 

From automation solutions and turnkey weld cells, to robotic solutions, training, and parts manufacturing, NRTC is working to assist companies in the manufacturing industry. Our goals are to assist in streamlining production, minimize downtime, and improve efficiency.  

Read more to find out the services that NRTC Automation provides to businesses in the manufacturing industry.  

AUTOMATION  

A current trend in manufacturing involves integrating automation into production lines, streamlining processes, as well as setting up for expansion and future automation. Adding turnkey weld cells not only improves the efficiency of production but can save manufacturing companies money on production and labor costs. It is estimated that labor costs for the US could shrink dramatically by 2025 with the addition of robots.  

Additionally, using the latest technology in manufacturing keeps production operating smoothly, and can keep a business more competitive in the market when compared to similar companies. Saving both time and money allows manufacturing businesses to stay at better price points for both consumers and manufacturers.  

NRTC has helped businesses of all kinds automate their processes, from small companies and startups to OEMs and large manufacturers.  

EMPLOYEE TRAINING AND STAFFING  

Training is an essential part of the manufacturing industry and its processes. Plus, proper training is a simple and effective way to prevent issues from arriving on the manufacturing floor. Trained employees reduce accidents, spot issues quickly, and ensure that maintenance plans are in place and followed for both machinery and the facility. Accidents can cost a business money, loss of time, and employees. In 2019, the aggregate cost of work injuries was $171 billion.  

NRTC offers training programs aimed at improving your manufacturing processes, through teaching the latest in robotics, hands-on training in programming and troubleshooting, and more.  

PARTS MANUFACTURING  

Outsourcing parts manufacturing can reduce labor and costs, increase efficiency, and give a company additional flexibility. There has been a trend recently to bring more manufacturing back into the United States, and NRTC Automation provides solutions for companies who still want to outsource but keep the production within the country.  

NRTC provides the highest quality parts manufacturing across a variety of industries, from automotive and rubber, to plastics. We can build and design a dedicated work cell to handle all parts of production needs.   

Our history speaks for itself, and we have worked with top manufacturers from around the world. We can customize solutions based on a company’s specific needs, and we are able to produce exactly what you require, freeing up your warehouse space and allowing production to ramp up.  

ROBOT REFURBISHING 

Many manufacturing lines have older industrial robot models that continue to undergo maintenance. Some of these robots may be a few years old, while others have been around for decades. With NRTC’s robot refurbishing service, we can extend the lives of manufacturing robots or recondition them to operate like new, saving both money and time.  

From a full inspection and basic testing, to cleaning, refurbishment, and even new-paint jobs, NRTC will breathe life back into your industrial manufacturing robots.  

NRTC Automation has Solutions  

NRTC has many roles in the ever-evolving manufacturing industry. We are proud to assist companies in bringing back manufacturing to the US, as well as assist businesses in growing, streamlining, and automating. From turnkey solutions to parts manufacturing, NRTC is deeply engrained in the industry and will continue to grow and support the community and its clients.  

NRTC is ready to help you improve your efficiency and productivity, and move you into the next decade up to par with the quick evolution of the industrial manufacturing industry. For more information, contact our team or learn more here.   

4 Reasons a Turnkey Work Cell Will Improve Your Production

Turnkey weld cells are an easy way to implement efficiency and productivity in manufacturing and production. Adding turnkey weld cells can keep companies on the cutting edge and reduce waste.  

Cells can be either pre-manufactured or customized for the specific needs of a company or production line. NRTC Automation can design, engineer, and build a turnkey weld cell to fit all of your production needs.  

Read on to find out four reasons a turnkey work cell will improve your company’s production and why you should add one to your manufacturing set up.  

INCREASE PRODUCTION  

One of the most enticing factors of a turnkey weld cell is its ability to increase production rates, without sacrificing quality. Adding work cells creates less of a margin of error than using manual labor, and has higher repeatability compared to in-house human workers.  

Many companies are also implementing turnkey weld cells with cobots, collaborative robots that work safely and seamlessly with humans, and have a lower price point.  

There are also companies that are installing turnkey weld cells into their fully automated facilities, streamlining the entire warehouse. These so-called dark warehouses are able to operate 24/7 and increase production through automation and AI.  

SAVE MONEY  

Implementing turnkey work cells is a cost-efficient method of production. Not only can turnkey weld cells replace expensive labor costs, but installing automation with work cells often solves the problem of staffing when there are shortages.  

A work cell is less expensive than buying new equipment individually and adding a custom turnkey weld cell to your facility can save you money in the long haul by increasing efficiency and production run time. 

Utilizing a turnkey work cell also minimizes downtime when manufacturing, which can cost an average of $260,000 per hour. The average downtime of production is roughly four hours, which can end up with an average cost of $2 million.  

A robotic weld cell reduces that downtime with a constant workflow. Having, for example, a work cell with automatic tool changers allows robots to quickly change applications, and speed up delays.  

Additionally, robots don’t require light or air conditioning, so manufacturers are able to save even more money by cutting costs for heating, cooling, and lighting.  

HIGHER QUALITY PRODUCT  

Implementing a turnkey weld cell increases the quality of your product, due to its high repeatability and precision. Self-contained in one cell, automation production assembles, welds, dispenses, and more. Choosing a well-planned robotic work cell, or using a custom design to fit your needs, can overall enhance your product quality.  

Choosing a partner like NRTC Automation ensures that you are being delivered high-quality services that will not only improve your manufacturing processes, but increase your revenue and cut production waste.  

A TOTAL SOLUTION 

A turnkey weld cell is an all-in-one solution to all your automation needs. Pick and choose the robots and their functions to fit your manufacturing needs. NRTC offers pre-engineered and customized work cells that are the ultimate turnkey solution.  

For companies of all sizes, a turnkey work cell is an easy and affordable way to effortlessly automate your company.  

NRTC is the Source for Automation Solutions 

We at NRTC Automation are dedicated to providing industrial automation and manufacturing solutions. Along with decommissioning and industrial robotic training services, NRTC is the key to integrating and streamlining your production facility.  

Contact NRTC Automation today to find out all the ways we can help you automate. 

Streamlining Your Manufacturing - 4 Ways to Overcome Problems

The manufacturing industry comes with its own set of problems and challenges. Waste tends to be the biggest problem in the industry, and comes in multiple forms, from product and time, to energy and money.  

There are ways to improve and work towards a lean manufacturing standard with sustainable productivity. Read on to learn four ways to overcome common problems that the manufacturing industry encounters. 

Automation  

Automating production is the easiest way to overcome many of the challenges that the manufacturing industry has. Many manufacturing companies that are currently integrating automation to their production are not only using it to streamline in the present, but to plan for expansion and future automation.  

Adding turnkey weld cells and industrial robots can save not only time, but costs. Labor costs for the US could shrink dramatically by 2025 with the addition of robots. NRTC customers alone have seen a 200 percent increase in throughput from implementing our turnkey weld cell solutions to their production processes.  

Using the latest technologies such as automation not only keeps a company’s production operating smoothly, but makes them more competitive in the market compared to similar companies. Saving time and money allows for products to stay at a better price point for both a consumer and a manufacturer.  

Training  

Training employees is a simple and effective way to overcome issues that might arise on a production floor. Thoroughly trained employees will be able to spot issues quickly, as well as ensure consistent maintenance plans for the facility and machinery.   

Training for employees also involves making sure all proper safety measures are being implemented Almost all safety related accidents can be prevented with proper training, preventing not only a loss of money, but a potential loss of time and employees. In fact, the aggregate cost of work injuries to the U.S. economy in 2019 was $171 billion.  

NRTC Automation offers training programs for a variety of tasks, from familiarizing your team with the latest in robotics to offering hands-on training in programming and troubleshooting.  

Analyze Data 

Automating production allows for manufacturers to look deeper into the data collected during production. Reading the results of production allows for weaknesses to be detected early, increases or decreases in production monitored, and adjustments be altered as needed on the fly.  

Taking a data-centric approach with data-forward software can more precisely measure success, and create a system of records so all employees and team members work with the same data. This creates clarity and clear communication across all channels.  

Regular Maintenance  

Regular maintenance should be a part of all manufacturing and production protocols. Along with daily, weekly, and monthly checks on robots and machines, reconditioning should be considered an important element in the maintenance cycle. Reconditing your equipment by cleaning out dust, removing old grease, replacing old parts, and regreasing joints. This will extend the life of equipment and ensure many years of use.  

NRTC offers industrial robot refurbishing to extend the lives of your robots and return their functionality to the highest caliber. From basic testing to complete overhaul, NRTC has a refurbishment solution to fit your needs. Additionally, we can help with restoring your robot to its visual best with our repainting services, as well as assisting with industrial robot repairs.  

NRTC has Automation Solutions  

NRTC Automation is dedicated to assisting with industrial automation solutions, from turnkey weld cells to robot repair and maintenance. Our additional assistance through options like engineering contract services and parts manufacturing. Learn more on our website, or contact us for more information.  

Why should you Outsource Parts Manufacturing?

Three Green Trends in Industrial Manufacturing

Green manufacturing is an important topic at the forefront of industrial manufacturing. Companies are constantly looking for ways to reduce waste and positively impact both the environment and their businesses.  

As companies look toward greening their manufacturing processes, here are three trends you can look for in the industry.  

Using Renewable Energy  

The idea of renewable energy isn’t a new one. Solar, wind, and water-powered energy exists, but how are companies harnessing them?  

In Europe, companies can purchase renewable energy certificates to offset their emissions. These certificates or credits are known as RECs equate to an amount of power generated from a green, renewable source. Purchased in megawatt hours, companies can strategize using wind, hydro, or solar to help move their company towards carbon neutrality.  

Improving Emissions through Automation  

Another way companies can reduce their carbon footprint is to look at their own emissions, and see what steps can be taken in order to reduce them. Automating production can be a tool in not only reducing your emissions, but monitoring them more closely.  

When industrial production is automated, businesses are able to automatically collect data and run reports on energy, emissions, and costs. A smooth production line overall creates less downtime, and that can equate to fewer losses of resources.  

Additionally, adding electric control modules, or ECMs, to your tool kit can help to manage and monitor the energy used from machines, lights, and more. You’ll be able to tell how much electricity a machine is using, and from there make decisions about upgrading or retiring machinery or lighting.  

Reducing energy consumption can not only save you money but directly affect the environment in a positive way, reducing the use of additional resources.  

Producing Energy In-House 

Producing energy in-house, specifically solar, is another route many companies are taking in the process of greening their industrial manufacturing. The German manufacturer ABB opened a facility in 2019 that can power itself on sunny days.  

The facility built in Luedenscheid, Germany can produce 1100 MW hours of power each year. That’s enough to power 340 homes for a year! We can expect to see more industrial manufacturing moving towards creating their own solar power in the upcoming years, in an effort to not only continue to green their processes but continue to save money.  

Smaller Steps  

While we highlighted these three trends, there are many steps companies around the world are taking in order to green their manufacturing. Keeping machines conditioned and running smoothly cuts down on energy waste, and ensures smooth production.  

When it’s time to replace existing robots, consider selling to a business like our sister company HGR, which buys and sells industrial surplus, keeping it out of landfills. And purchasing a refurbished robot keeps the lifecycle of machinery extended and away from the dump.  

Streamline and Refurbish with NRTC Automation  

We also refurbish industrial robots here at NRTC, extending the life of your machine, and aiding you in reducing waste and saving money. NRTC also designs and produces turnkey weld cells, created with refurbished industrial robots. We have a focus on efficiency, maximum throughput, and minimal waste.  

To learn more about our green automation solutions and refurbishment options, contact us today.  

Designing Your Weld Cell - 3 Things You Need to Know

Robotic weld cells can help production lines increase productivity and efficiency, as well as keeping costs lower. While individual industrial robots can be great, weld cells are pre-engineered to run production according to a job specific need.  

In a constantly evolving competitive economy, adding elements like robotic weld cells keep companies on the cutting edge and able to focus on efficiency. And with many production cells cutting down on waste, there is not only higher profit, but an increasingly better relationship with the environment.  

There are important steps and processes to consider as you are designing a weld cell for a production line.

Continue reading to learn three things you need to know before designing your weld cell.  

MAKE A PLAN 

It seems like a simple and straightforward idea, but knowing exactly what your work cell needs to do is an important first step when designing. Asking questions like, “What will my work cell be producing?” is key to knowing exactly what parts to include in the cell, and how to program it.  

Each work cell that is in existence has not only specialized parts, but unique programming to both the task and machine. Being as specific as possible in this early stage helps streamline building and programming, and ensures less down time as you start to design.  

Part of making a plan should be developing an outline, including mapping out tasks before production and building begins. A solid outline will act as a framework for production, and make sure all steps of the automation process will be included.  

PICK YOUR PLAYERS  

Once a thorough plan is created with an outline, it’s time to select the industrial robots and parts for your weld cell. As you are searching for robots, there are a few important points that should be considered:  

• Robots' Reachability – This can determine the number of robots and spacing.  

• Payload Limitations – Consider what you are producing, and the weight and size limitations of the equipment you are selecting.  

• Precision Capabilities – Determining what you will be producing and the finer nuisances that might be needed can separate one robot choice from another.  

• End of Arm Tooling (EOAT) - Knowing what equipment you will need on the end of your robotic arm can help to narrow down purchasing options.  

• Cycle of Time – The speed of the robot is a good indicator for a production line’s efficiency and speed.  

In considering what robots to select, a positioner also needs to be chosen. The positioner is what will hold or contain your product that is being manufactured. It can be mobile or fixed, with factors such as adjustable height and weight capacity being taken into consideration when selecting an option.  

LAY IT ALL OUT  

Once you’ve developed an outline, and selected your production equipment, it’s time to create a layout. This is the most important aspect of design, as you are figuring out the placement of both robots and positioners to achieve maximum efficiency.  

Consider how your work cell will be laid out. Will it be in a linear fashion, or will it have turns, or changes in direction?  

As you lay it out, make sure to think about not only how it will fit into a manufacturing facility, but how staff and employees will be positioned in the workflow. Safety is always the most important factor, and protecting and making sure employees are comfortable should be a top priority.  

NRTC Automation Solutions  

NRTC specializes in custom turnkey weld cells for manufacturers of all sizes. From startups to top automotive OEMs, all of our work cells are refurbished, ensuring turnkey automation that is ready-to-work and affordable.  

For more information on our automation solutions, turnkey weld cells, and parts manufacturing, contact us or visit our website for more information.  

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.