4 Ways to Improve Productivity in Manufacturing

Maintaining high productivity empowers you to make more by using your time and resources effectively. However, many manufacturers encounter high costs due to downtime, inefficiencies and errors in the production process.

It’s time to make changes that directly address your company’s most challenging obstacles. These productivity tips for manufacturers can help your business optimize its equipment, processes and people.

1. Upgrade and Optimize Machinery

Equipment that runs efficiently and produces finished items with little waste maximizes your revenue and productivity. Using precision CNC machines reduces scrap created during manufacturing and prevents common errors.

When yourÌýequipment needs performance improvements, a full replacement can be costly and require further changes to your workflow. CNC machine maintenance and upgrades, including rebuilds, can provide a faster return and reduce downtime in manufacturing.

Working with ÌÇÐÄ´«Ã½ can help you determine whether new machines are the best choice for your operations. If you’d see more benefits from turnkey programming or rebuild options, we can guide you to those, too.

2. Streamline Processes and Workflow

Identifying improvement opportunities for manufacturing process optimization in your current workflows can significantly increase productivity.

Production methods like lean manufacturing emphasize efficient layouts, minimized movement and batched jobs. Applying these principles to your operations can dramatically shorten lead times. Flexible manufacturing systems (FMS) are excellent options for manufacturing lines that see rapid product changes. You can also leverage automation to take over repetitive tasks, leaving manual work for processes that require more attention.

3. Operator Training and Maintenance

Well-trained operators reduce errors and downtime. Training courses or resources can equip your team to enhance safety, minimize waste and keep your facility running smoothly. Beyond investing in your operators, adopting preventive maintenance schedules and predictive monitoring can limit equipment breakdowns, further maximizing uptime.

When you need maintenance, ÌÇÐÄ´«Ã½’s dedicated service arm and exclusive partner, Tomel Machine Tool Services, canÌýperform rebuilds and other upkeepÌýto ensure your equipment remains precise and efficient.

4. Monitor Productivity and Continuous Improvement

Identifying the most relevant KPIs to your manufacturing operations gives you a measurable way to see when productivity lulls or increases. Track cycle time, scrap rate and machine uptime to see patterns and adjust your workflow or processes based on that data.

You can use these insights to make small changes to standard operating procedures (SOPs), optimize tool changes and adjust material handling practices.

Manufacture More With the Right Support

If your business needs to improve manufacturing productivity, review your workflows, training, equipment and maintenance schedule to streamline your operations.

Ready to increase CNC machine efficiency in your facility? ExploreÌýnew models from ÌÇÐÄ´«Ã½Ìýor contact us toÌýschedule a consultationÌýfor rebuild or maintenance services.

CNC machining supports high-value manufacturing in numerous industries. Each relies on accurate measurements down to the micron to ensure product functionality. Without that level of accuracy, CNC machines cannot produce quality goods.

Investing in the accuracy and precision of machining equipment can mitigate the risk of faulty or imperfect products. Operator training, software updates and inspection systems are just a few of the ways you can improve your facility’s manufacturing processes.

In this article, we examine precision and accuracy in CNC machining and discuss the many ways you can enhance them in your machining processes. ÌÇÐÄ´«Ã½ offers advanced machining solutions that can significantly improve both precision and accuracy in your CNC operations.

Precision vs. Accuracy in Machining

In machining, precision and accuracy refer to two distinct concepts. Both have a deep impact on the final quality of manufactured products and their compliance with industry standards.

Precision is the consistency of measurements across products. After manufacturing, the entire line of products needs to function in the same way. Spark plugs, for instance, are designed to fit precisely in vehicle engines. If the spark plugs for a given engine vary in size by even centimeters, only some of them will be usable. In this way, there is a direct connection between precision and profit.

Accuracy is the proximity of a given product to the intended design. Where precision focuses on repeatability, accuracy focuses on perfection. If products do not adhere to their design measurements, they will not be able to carry out their intended purpose, even if they are interchangeable with one another.

CNC machining must excel in both precision and accuracy to consistently produce functional, high-quality products.

How Precise Can Machining Be?

CNC machining is extremely precise, capable of fabricating products with measurements that differ by fractions of an inch. The typical CNC machine has a tolerance of about ±0.005 millimeters, whereas high-end machines can push that number as low as ±0.002 millimeters. Some ultra-precision machines that fabricate products for the aerospace and medical industries even yield tolerances as narrow as 1 to 5 microns.

This level of precision is extremely impressive and promotes uniformity across manufacturing processes. However, the CNC machines that produce these results are still not able to achieve ultimate precision.

Factors Affecting Machining Precision and Accuracy

The precision and accuracy of CNC machines are impacted by a range of circumstances and conditions. Some may lead to microscopic and unavoidable imperfections, while others can lead to large defects. These factors include:

• Machine quality, calibration and maintenance:ÌýPrecision and accuracy vary from machine to machine. AÌýfive-axis machine, for instance, provides a level of quality that a three-axis machine cannot. However, each machine must also be calibrated properly. Spindles, ball screws and guides must all be aligned for the job, and each component must be kept clean and functional to perform at a high level.
• Machine age:ÌýAll machines experience wear and tear over time. This damage can be mitigated by regular inspections and upkeep, but eventually, every CNC machine will reach the end of its life and experience a gradual drop in both precision and accuracy.
• Operator skill and training:ÌýWhile computers play a key role in controlling CNC machining, operators are still required. TheyÌýprogram the machinesÌýusing geometric code, conduct repairs when necessary and ensure the machines are manufacturing products within acceptable tolerances. Their level of skill and training directly impacts the quality of CNC machining.
• Thermal drift:ÌýWhen materials are exposed to the intense heat of CNC machines, they tend to expand slightly. This phenomenon is called thermal drift. Cooling agents are typically used to minimize thermal drift, but it often stillÌý.
• Machine vibration:ÌýDuring the cutting process, CNC machines naturally experience intense vibrations. Dampers and rigid designs can mitigate these vibrations, but malfunctions and poor workpiece placement and fixturing can exacerbate them. If your machine regularly experiences excess vibrations, it may be time for maintenance or additional training.

Large-scale manufacturers worldwide rely on flexible manufacturing systems (FMS) to accomplish demanding outputs. What is flexible manufacturing, and why is it so important? These highly adaptable, automated machining setups can easily manufacture various products and handle rapid production changes. These factors are vital for businesses that need to change product design, type and volume frequently with as little downtime as possible.

Learn how flexible production systems work and their benefits to businesses in this guide by ÌÇÐÄ´«Ã½. We specialize in integrated U-axis contour head machining centers and have decades of experienceÌýwith challenging manufacturing projects. We also do in-house integration and can work with integrating partners.

Flexible Manufacturing System Definition

A flexible manufacturing system is a highly adaptable production setup that uses automation technology. These custom systems include a centralized computer that controls various machines, material handling systems and robots. They exist to offer manufacturers production flexibility, as you can adapt the system to accommodate varying batch sizes, product designs and process sequences. FMS are almost entirely automated to reduce labor costs and improve productivity.

Components of Flexible Manufacturing Systems

FMS comprises modular components that manufacturers can adapt and reconfigure to meet changing production requirements. The core components of an FMS include:

• Work machines:ÌýEach FMS has a unique combination of workstations to suit the manufacturer’s production requirements. These can be various robots, computer numerical control (CNC) machines, tool changers or inspection and assembly stations. Each workstation performs the required processes to turn materials into a finished piece.
• Material handling systems:ÌýFMS requires multiple material handling systems to achieve complete automation. These hold and transport parts to each workstation in a specified order. There are also systems to store the parts and materials before and after processing. Examples of material handling systems are robots, conveyor belts, automatic pallet changers, automated storage and retrieval systems and automated guided vehicles.
• Control computer system:ÌýThe control computer system is the main component of an FMS that automates the entire process. This system houses a computer, programmable logic controller (PLC) and the necessary software. It allows operators to input programming toÌýcontrol the movements and sequenceÌýof each machine in the setup. It also monitors the machining process and updates the operator when issues arise.
• ±Ê±ð°ù²õ´Ç²Ô²Ô±ð±ô:ÌýWhile FMS is mostly automated, machine operators are still necessary to control them. Trained personnel instruct the FMS to perform specific tasks, start and stop the process, and make adjustments when needed. Once started, the FMS can operate 24/7 until the material runs out or the instruction is complete.

Routing vs. Machine Flexibility

Flexible management systems can offer two types of flexibility — routing and machine flexibility. Some advanced systems can even do both.

Routing flexibility refers to the system’s ability to change production sequence or order. This type of flexibility is essential when a machine breaks down or material runs out. The system can adapt and change the processing sequence to continue producing parts while operators resolve the issue. This also helps shift production to a new product requiring a different manufacturing order.

Machine flexibility means multiple machines can perform the same task within tight machine tolerances. When one machine stops working, the others can take over and produce the same result. This type of flexibility is also vital when demand for a product rises. The manufacturer can increase output by diverting other machines to manufacture the same product.

The Advantages of Flexible Manufacturing Systems

Manufacturing automation refers to the use of technology in manufacturing processes to reduce human intervention. Automated machinery — often controlled by computers and programming — can complete repetitive tasks quickly and accurately. It can also take over dangerous tasks to improve worker safety. This assistance streamlines manufacturing operations and allows workers to use their skills for more essential tasks.

With material and labor issues rampant throughout the industry, manufacturing automation is now more critical than ever. Automated machines primarily benefit businesses by helping to increase output and grow profits. In this article, you’ll learn more about the different types of automation and how they improve manufacturing. We’ll also explain how ÌÇÐÄ´«Ã½ helps businesses in various industries integrate automation into their setups with innovative machining centers.

Why Is Manufacturing Automation Important?

The manufacturing industry currently faces various challenges. Most notable are the rising material costs and labor shortages. While inflation rates are slowly reducing, businesses and consumers are still experiencing the effects of aÌýÌýin 2022. With higher inflation rates, raw materials and energy cost more. Greater expenses make it hard for businesses to profit without charging consumers more for the finished product. This is another issue, as higher inflation rates reduce consumer purchasing power.

Labor shortages also impact businesses. With fewer qualified workers, manufacturers find it hard to fill essential roles and complete core business operations. Unskilled labor can also lead to more errors and waste, which increases expenses. Automation offers businesses the chance to overcome these challenges by reducing costs and reliance on manual labor.

Types of Automation in Manufacturing

Various forms of automation are available today. Depending on your requirements, you may need a specific type or a combination. Learn more about each type below to understand which one is best for your needs.

1. Fixed

Fixed or hard automation refers to machinery that can only perform preprogrammed, set tasks or processes. It’s complicated and expensive to change their programming, as it’s often tied to physical configuration and components like wiring and gears. However, these machines can perform specific tasks at high speeds and produce consistent and accurate results each time.

Manufacturers that create high volumes of identical units and use repetitive tasks benefit the most from fixed automation. Once set up, these machines can complete the same task repeatedly with limited human input. Fixed automation machines work well in assembly lines and conveyor systems.

2. Programmable

Computer numerical control (CNC) machining centers are powerful, innovative equipment that can benefit multiple industries. Their complex capabilities allow companies to improve their machining quality while reducing manufacturing time. However, they are a substantial investment and require careful consideration before purchase.

In this guide, you’ll learn what factors you should consider when selecting a machining center for your business. We also cover some common applications for CNC machines within the industrial, energy, automotive and aerospace industries.

Most Popular CNC Machines

The two most popular and used commercial CNC machines are the lathe and mill. They’re also the best CNC machines to start with, as they can machine both simple and complex parts, depending on your needs.

• Mill:ÌýA CNC mill rotates a cutting tool to remove material from a stationary workpiece. It’s suitable for parts that need flat surfaces, grooves or holes.
• Lathe:ÌýA CNC lathe turns the workpiece on a central axis while the stationary cutting tool removes material to shape and profile it. It’s best for cutting cylindrical parts.

Some other CNC machines include routers and plasma, laser and water jet cutters.

How to Choose a CNC Machine

The best CNC machine for your business is one that falls within your budget and has all the required features. Below are five factors you can consider to narrow your options and find the optimal machine for your application.

1. Functionality

CNC machines have various tools that perform different functions. They can mill, grind, contour, turn, drill, tap, bore, rough, face and more. Decide what tools you need to achieve the desired shape and choose a machine accordingly. Sometimes, you’ll use tools that are similar in nature but require different machine functionality. For example, you can use the same tool to turn a workpiece as you can bore a workpiece, but the machine would need different functionality to perform either cut.

You can also consider a CNC machine with an automatic tool changer to swap out tools without manual intervention. For example, Trevisan’s horizontal milling machines featureÌýan integrated facing headÌýthat can perform various functions within one machine. We also offer a more specializedÌýModulo Equipe turning centerÌýthat can hold up to six different tools per turret.

2. Speed

A CNC machine has two main speeds — the spindle speed and feed rate. Feed rate is how far the tool moves across the workpiece during one spindle revolution. It’s measured in inches per minute. Spindle speed is the rotational speed of the machine’s spindle, measured in revolutions per minute.

Speed is necessary to consider in your selection, as different applications need specific feed and spindle rates. The right speed will maximize the machine’s efficiency and precision. In addition, the right feeds and speeds are essential for the quality of the cut or material removal. Speed will also affect how much power the machine uses and how quickly the tool wears down.

3. Axes

CNC machines have varying axes for tool movement, and most CNC machines have around two to five axes. A machine with more axes can complete detailed, complex designs and cut the workpiece from multiple angles. A CNC machine with fewer axes may be sufficient if you have simpler requirements.

Some processes require a machine with a specific axis to perform the necessary functions. For example, some processes would be more efficient if you could adjust the diameter of a hole without manually moving the tool. Horizontal CNC mill machines fromÌýÌÇÐÄ´«Ã½Ìýfeature an additional U-axisÌýthat meets this need.

4. Weight