Monthly Archives: December 2020

Types of Production Planning

If you work in a manufacturing plant as a supervisor you have heard the words “production planning” many times. This is the procedure that they use to decide just how many goods to manufacture. For the company to be successful efficiency is important. They do not want to over produce products and then have them just sit in the warehouse. That is profits down the drain, so to speak. A company wants to make sure that they are producing enough products to meet the demands. There are many different forms of production planning that goes under various titles in the world of business. There are three main types that many businesses use.

Batch production planning

This type of production planning involves producing many identical individual products from the same batch of raw material. For example, a seamstress would take some cloth and produce five individual identical dresses. In a manufacturing plant that produces many different products this can advance the efficiency of the employees and machines to produce one large batch of an individual product at the same time. In a factory, for example, the machines may be set up to produce a group of peas in cans, followed by a group corn in cans. Setting up the machines to follow this schedule is more efficient than changing the machines to produce a can one at a time as they are needed.

Job-or project-based production planning

This type is generally used in smaller businesses where one team or one person does the production of services or goods. A jewelry maker that makes custom engagement and wedding rings is an example of this type of production planning. Film production is a team so this is the type of planning they would use. Job-and project planning is very customizable to meet the requirements of the business and the customer. It should not be used if you are creating a flow of production that is consistent.

Continuous or mass production planning

This one is used often to create products that are massed-produced and generally used by large factories to produce a steady flow of products. For this process to be cost-efficient, a demand for this product must be regular. The production services must also be streamlined. This is so the products go from one-step of the making the product to the next step effortlessly. This requires demanding pre-planning of production flow and layout.

In conclusion

In production planning, determining the right method for a business will normally depend on mathematical calculations and market forecasting. Some companies will use production planning software to capitalize on the company’s production capacity and to measure planning strategies cost-effectiveness. Through control, the methods of planning are often made to make the most of on the company’s potential.

How Trump’s Trade War Will Hurt You

Trump followed through on one of his campaign promises by starting a trade war with our trading partners to help reduce our enormous trade deficits. The first shots fired in this war are tariffs on steel and aluminum imports in an attempt to help American steel and aluminum producers.

As with most wars, this one will have unintended consequences that will actually hurt the people it’s intended to help and make the problem worse. Trump’s presumed intention is to help the American economy by balancing the trade deficits, protect American companies and save American manufacturing jobs. In practice, a tariff on imports will make all three of these problems worse for these reasons:

American Manufacturers Will Be Less Competitive

If you want to make American manufacturers more competitive, then your aim should be to lower their costs of production. Since aluminum and steel are used as a raw material in the production of many manufactured goods, this tariff is crippling. Any company that uses aluminum or steel (cars, airplanes, appliances, construction) now has to pay more in order to produce their product. Many of these companies are hanging on by a thread trying to compete with lower cost areas of the world. Now their costs just went up even more and many will go out of business as a result.

American Steel and Aluminum Producers lose their American customers

While I am sure somewhere in Trump’s brain he thinks he is helping American Steel and Aluminum producers, he is actually hurting them. Even though these producers will see higher prices for their products, they will suffer because THEIR customers – the manufacturers that use steel and aluminum – will go out of business. Obviously, not all of them will go out of business, but even the healthier companies will scale back their business due to lower sales. Why will their sales be lower? That brings us to the final point…

Consumers pay more and lose their jobs

Because the costs of production for these American manufacturing companies will increase, many will have no choice but to increase the price of their products. Consumers, especially American consumers, don’t like higher prices. Most won’t know why prices went up but they will speak with their wallets by purchasing fewer of these products. As a result, American manufacturers will experience lower sales.

What happens when a company’s sales decline? Often, they lay some workers. If you’re afraid that robotics and machines are replacing humans jobs, wait until you see how fast those jobs disappear in a struggling economy with declining revenue.

And that is the irony of this bone-headed Trump move: he thinks he is helping Americans “win” again, but he is actually giving them higher prices and a pink slip.

The Future of Manufacturing

From catching a ride to getting instant medical attention, smartphones have completely changed the way people live and carry out their daily tasks. In a similar way, the rapid evolution of operating technology and production means have transformed manufacturing. Innovative companies like Tesla is the best example of how technology can materialize the seemingly impossible ideas and change our view of reality. Modern food processing equipment, robotics, sensor technology, and smart machines are no less striking.

There is something that drives manufacturers to constantly explore means for improving efficiency and agility. Managing market volatility is one of the biggest challenges manufacturers face today. In order to successfully handle this challenge, manufacturing leaders need a sound combination of speed, agility, and responsiveness. The characteristic of being agile and responsive can also help companies deal with a number of challenges, for example, fluctuating raw material costs.

Most of the successful companies focus on improving production processes and enhancing customer relationships. Small companies even pay more attention to meet customization demands and improve productivity. No matter the size of a company, the manufacturer struggles to maximize capacity utilization and achieve annual cost reductions. Implementing innovative production solutions carefully is the only way to achieve these objectives.

Industrial automation technology indicates that there is never any shortage of opportunities to grow and remain profitable. A business manager has to identify strategic opportunities and technologies that can offer the greatest profit potential. It is also important that a new solution should be in compliance with a company’s competitive differentiators and core capabilities.

It is highly likely that by the year 2020, business owners in every industry will have invested millions of dollars in a broad range of automation and fabrication technologies. Nano-manufacturing, 3D printing, artificial intelligence, smart machines, and the Internet of Things (IoT) will dominate the future.

Investment decisions can depend on a company’s priorities and objectives, market conditions and forecasts. Introducing new technologies is subject to a thorough cost-benefit analysis. The way of conducting cost-benefit analysis can vary from industry to industry.

Automation technologies such as robotic welding, smart sensors, quality control systems, metal fabrication, magnetic inspection, and material handling equipment can help companies achieve the following objectives:

  • High productivity
  • Improved data availability
  • Faster responsiveness to customer expectations
  • Production flexibility
  • Improved employee engagement

Small companies must learn how to implement automation and improve productivity in a cost-effective manner. The success in manufacturing now largely depends on how efficiently a company can adapt and meet market expectations.

Benefits Of Manufacturing Paper Bags Using An Eco-Friendly Paper Bag Making Machine

The paper bags have gained popularity since then the plastic carry bags is facing ban in various countries and cities. The product is manufactured with two ways; either traditionally, i.e. with the hands which is a labor intensive method or technologically i.e. with the help of automatic machines. The second method is capital-intensive. In other words, it requires less labor and more capital for purchasing land and machines. On the basis of the core business of the Paper Bag Making Machine Manufacturers, the machine has abilities to manufacture two different sized output with the fine finish and seamless quality.

Amazing Benefits Of Using A Paper Bag Making Machine For Manufacturing Paper Bags:-

  • Fine Quality: The foremost benefit of manufacturing paper bag from the automatic machine is the finest quality one can achieve throughout the process of production. When we make paper bags from traditional methods, the quality of the product doesn’t remain same throughout the process of production. It is quite difficult to manage the same level of quality with each unit. The paper bags manufactured through machine give similar and precise quality each time.
  • Saves Expenses On Labor: The introduction of an automatic machine for manufacturing process cut down the need for labor in the paper industry. A person is required to change the roll of paper only and collect the finished product after the completion of the production process. This saves unnecessary expenses on labor and you can invest in machines and land instead of labor. More machine and land can lead to double the production level of the business within the same time period.
  • Streamline Production Level: The quality and fast production are two key factors of any production process and the automatic machine for the purpose of the production satisfy both of these factors while streamlining the level of production. It literally saves time in terms of money and maximizes your production level when it is compared to the handcrafted methods. You can actually increase your production with time.
  • Saves Manpower: The automatic machine saves the working capacity of a person and helps to maximize the production level. Both the man and machine have the different working capacity. A machine can work more effectively than a person and require fewer work breaks than a man. You can have a good level of production with the machine. A machine can multiply your production level within the same time. However, a person can only increase the production because every person has the different working capacity.

Computer Use in the Food Manufacturing Industry

Food manufacturing and processing is one of the success stories of the global economy. Food production is now not just a local industry as food products are now transported across the globe allowing a huge variety of products to be available on our supermarket shelves.

One of the reasons for food productions success has been the embracing of modern technology that has allowed many processes in the food production industry to be automated.

The food industry does pose unique challenges when it comes to automation and computerisation such as the prevalence of water in food production areas. Various laws and good working practices mean that food production areas are regularly washed or hosed-down. This can cause obvious problems to computer or touchscreen if they are used nearby as water will have catastrophic effects on any computer system.

Many food production of manufacturing areas turn to waterproof computer enclosures to protect their computer systems from wash down. Industrial computer enclosures are designed to international guidelines to ensure they can operate safely in washdown environments with the waterproof PC enclosure even allowing the systems to be hosed down themselves.

The European IP 65 or International NEMA 4 rating system are often used to describe the waterproofing of a computer enclosure. Many wash down areas contain IP 65 computer enclosures as they can also be manufactured out of food grade stainless steel ensuring they don’t corrode and can continually be kept clean.

Waterproof LCd enclosures and waterproof touchscreen enclosures can also be manufactured from the same material.

3 Hidden Benefits of Precision Machining

Many companies who already hire contract manufacturers to carry out precision machining manufacturing methods – or even those who already use these methods of production on their own business premises – will be familiar with some of the most well known benefits of precision machining. Including CNC grinding and CNC milling, these techniques have many advantages.

These include the elimination of human error as well as increased productivity due to the consistently high quality and rapid production capabilities of the equipment. There are also other widely accepted advantages of these production methods, including the fact that these can be very cost effective in the long run and can give companies that use them a distinct competitive edge.

With that said, there are several hidden benefits of precision machining for companies that some professionals might not have considered yet; here are three less widely known advantages that are well worth bearing in mind if considering using this production method.

First of all, precision machining methods such as CNC grinding and turning are very environmentally friendly methods of production, namely because there is far less waste of materials than with other, more conventional production methods.

This is primarily down to the fact the very precise and accurate calculations are made by computers before the manufacturing takes place, and these calculations direct the entire production process. This eliminates human error and ensures absolute consistency each and every time a part or component is produced.

As a result, there is far less material wasted as these accurate measurements are made and executed without fault each and every time. This is not only avoiding a waste of money by the company spending a proportion of their budget on producing items that are ultimately useless for their purpose, but it is also avoiding wasting valuable resources.

The second hidden benefit is that precision machining techniques such as CNC grinding and turning can actually benefit employees by keeping them far safer during the manufacturing process. Traditionally, operating heavy machinery in the production process is very dangerous, resulting in many accidental injuries and deaths each and every year around the world.

However, this has all changed with the advent of computer controlled and operated precision machining, where it is necessary to have skilled workers and engineers oversee processes without getting physically involved in the dangerous aspects of machining parts and components, as this is all done by tools directed by computers.

This can help keep the workforce safe and secure on the job, and drastically reduce the risk of serious injuries and accidents. This can in turn boost employee morale and job satisfaction, which of course has a huge positive impact on the running of the company and the success of the business in general.

Lastly, a final hidden benefit of precision machining techniques such as CNC grinding and milling is that they are extremely adaptable, and can be used to manufacture a variety of components and parts for numerous different industries. This is beneficial for companies as they do not have to worry about the equipment they purchase becoming obsolete in the near future.

Although there are various types of precision machining tools, once purchased these will be fit for many different manufacturing purposes for years to come. These items are therefore a very solid and reliable investment to make for any company looking to manufacture their own parts and components on site.

These are just three of the hidden benefits of precision machining tools. From providing a very resourceful solution for the manufacturing industry to offering ultimately adaptability and flexibility, there are many reasons why companies might want to consider investing in these items of equipment.

If they prefer, there are also many contract manufacturers offering their services that use high quality precision machining tools in their production processes.

Experience Enhanced Productivity With Lean Six Sigma, Here Is How

As the name suggests, lean six sigma methodology integrates the principles of lean manufacturing with those of Six Sigma. Many manufacturing organizations that have implemented the methodology have experienced enhanced productivity with a significant reduction in human resources, time and capital resources.

But why are organizations of all shapes and sizes want to adopt the method? What advantage does the method offer? In this article, we have attempted to answer these questions.

Let’s first understand what exactly lean methodology is

Lean is basically a process aimed at continual improvement based on increasing the value for customer. The main objective of the methodology is to eliminate everything that does not contribute to what customers exactly want.

Lean manufacturing methodology comprises of a number of principles and methods such as:

  • Kaizen – It aims at continuous improvement based on employees’ suggestions.
  • Kanban – It is a ‘pull’ system aimed at pushing inventory into warehouse for “safety stock” in order to deal with any change in demand due to changing forecasts.
  • TPM – Total productive maintenance reduces equipment downtime.
  • TQM – Total quality management emphasizes on improving quality of products and services being offered.
  • 5S – It aims at improving quality and efficiency through cleaning up and getting organized.
  • SMED – The principles of Single-Minute Exchange of Die minimize the time needed to change a machine or production line for production of different products.
  • Poka-yoke – It is used to eliminate the possibility of errors.

Lean is primarily used to streamline manufacturing and production processes by cutting out unwanted steps involved to add value to the production and services.

Approach a consultant for intense lean manufacturing assessment.

What exactly is Six Sigma?

Six Sigma is a quantitative method aimed at improving quality in manufacturing using data collection and measurement. The method basically addresses errors involved in both the production and design of a product or service. It consists of two approaches named DMAIC and DMADV.

Let’s understand both the approaches.

DMAIC

DMAIC refers to a five-step process used to improve an existing product. The five steps are given below:

Define the Project – At this stage, goals, resources, and limits of a project are determined.

Measure – Then, data about the current system or process is collected.

Analyze the Data – Data collected is analyzed to find the root cause of the error.

Improve – Design and implement changes (poka-yoke and standard work) are introduced to the process to address the error found. Some techniques that are used include design of experiments, poka-yoke and standard work.

Control – It refers to providing a system to monitor and adjustments to maintain and improve on what was attained.

Another approach is DMADV which is embraced to improve an existing product or service’s quality. The major steps involved in DMADV include:

Define – Establish the methods that are needed to be used and the goals are defined of the project.

Measure -Characteristics that are critical to quality (CTQ), production process capabilities, capabilities and limits, and potential risks are determined.

Analyze – Develop and test design alternatives.

Design – The best alternative based on customer requirements is determined.

Verify – Authenticate the design in harmony with the goals of the project and make adjustments on the basis of feedback and new data.

When both the methodologies are integrated high level of customer satisfaction is aimed to achieve.

Consult a Lean Six Sigma Manufacturing Consulting firm to know how lean six sigma can improvise your manufacturing process.

Advantages of Tablet Contract Manufacturing Services

Contract manufacturing has easily become one of the most cost-effective ways of managing the growing demand for products without compromising on their quality. A professional manufacturing firm offering tablet manufacturing or encapsulation services at a lower cost and in a licensed facility is a far better alternative than producing the products at an in-house facility without the competence or expertise in the field.

One can understand the role of a contract manufacturing firm by understanding their advantages and benefits of using it. The tablet manufacturers specifically benefit from such firms as they witness an increase in their production without having to invest a lot of capital.

Some of the main advantages of using a tablet contract manufacturer include:

Quality Improvement

With professional contract manufacturers providing timely and competent manufacturing services for a pharmaceutical brand or product, the tablet manufacturer can focus on the key aspects of its core competencies. The research behind the quality and effectiveness of the product becomes the central point of attention for the manufacturers and they can serve their consumer base in a better way. The use of better ingredients, proper research and development process and channelized experiments are possible with impetus being laid on satisfactory results.

Expert Assistance

A seasoned contractor has been offering quality and satisfactory services in tablet manufacturing for over a long period of time. The firm is proficient enough in handling huge production projects as well. They offer their licensed facility for production purpose. They have the right expertise, adequate resources, and adhere to cGMP guidelines for quality production.

Quick Time

The availability of proper equipments and good resources makes it easier for contract manufacturing companies to develop products in quick time. Since, the manufacturers are dedicated to the production process, they focus on maximum production. Some of the major production services offered by them include tablet manufacturing, encapsulation, capsule manufacturing, tablet packaging and labeling, and also producing products.

Cost-effectiveness

Hiring a professional tablet contract manufacturer is a cost-effective way of producing or developing pharmaceutical products. One does not have to invest on the expensive infrastructure, equipment and other material for the services. There are many contract manufacturers offering premium services at competitive prices in the market.

It can be inferred from the above discussion that contract manufacturers for tablets and capsule production provide both a cost-effective as well as time-effective way to produce pharmaceutical product in bulk. Moreover, one is spared the effort of research and development related to the manufacturing process.