Why automate?  Explanation of justification and impact

Why automate? Explanation of justification and impact

Do you want to integrate automation into your production process but don’t know where to start? Perhaps your biggest obstacle is justifying the costs associated with the change. Effectively communicating the reasons and ROI to all stakeholders in this important change is a necessary starting point.

Justify the need to automate

Rising production demand usually makes the simpler justification for automation with quality control and repeatability a close rival. As COVID has taught us, maintaining a full staff of trained and qualified operators can be a challenge, and automation reduces dependence on human labor.

Consider the basic concept of Lean Manufacturing. In short, Lean is an approach designed to provide efficient and competitive manufacturing. Sounds simple in theory, right? But there is a lot to be done to optimize efficiency. Simply put, the most profitable operations minimize waste and optimize their greatest assets. They lead initiatives that ensure maximum productivity and profits, while ensuring that their manufacturing processes are focused on quality.

Your machinery and your people are two of your biggest costs. In a world where everyone wants it faster and cheaper, and regardless of whether you have adopted Lean methodologies or not, every manufacturer must keep an eye on the goal of how to deliver the highest quality product with the best and most margin. favorable.

Do you want to determine if it is necessary to automate? Ask yourself:

Can you keep up with peak demand?

Are your customers demanding faster deliveries?

Is your HR cost unpredictable and do you have enough qualified staff?

Is your process repeatable?

Designing the solution: case study examples

At ELSNER, we start a project with detailed discussions with our customers. Our engineers and designers track the current manufacturing process and determine what is needed to achieve manufacturing goals. Then they discover the best technology to eliminate cumbersome and time-consuming tasks. Here are some examples of how automation has a significant impact on manufacturing results.

Coreless stuffing rolls get a boost

A medical supply company needed to replace an outdated slitting-and-rewinding configuration for core-less cotton rolls. The process was so laborious that operators had to rotate every 30 minutes. We developed and built them the CUPR-50, an automatic small roll rewinder that has saved them time, increased efficiency and made their operators very happy. The machine used an automated web guiding, integrated recipe-based controls, and an automated rewind shaft recycling feature that improved quality and reduced labor.

The production of a complex surgical drape becomes fully automated

A robotic product manufacturer needed to automate the production of a complex surgical drape. We have adopted a fully manual process and fully automated it using several processes including tube forming, ultrasonic sealing, die cutting, robotic pick and place and gantry solutions. The workforce went from 14 employees to 2 employees and significantly increased the number of tents produced.

It is worth noting that the automated solution was designed with tight tolerances into account. One process takes the metal ‘buttons’ from a bowl feeder and places them on the passing belt, easily reaching the customer’s tolerance of +/- 1/32 ”. Another pick and place operation uses a vision system to guide a robotic arm towards its target with repeatability measured to the thousandth of an inch and positioned perpendicularly on a tape that passes within 1/16 ”.

Automation for reverse osmosis filtration elements: less manpower, more consistency

A filtration company was assembling filter elements with a series of manual steps to fold the membrane leaves, apply glue, build packs, roll the spiral element, and apply protective tape to the outside.

We started by automating the feeding and cutting of the membrane, the application of the crease protection tape, the cutting and positioning of the mesh spacer, and the folding. We have more than doubled leaf production with our automated membrane folder, the ELSNER EMF-42, which produces up to 10 leaves per minute.

We have automated the placement of the glue bead on each leaf, an operation performed manually by a team of two operators. The automation of glue placement not only reduced manpower and worker fatigue, but also greatly improved the consistency of glue line placement. Having repeatable beads, one on top of the other, increased the active area of ​​the final elements. The shift to automation reduced manpower, increased production, resulting in a superior product.

Automation for future growth

All things considered; you can understand why automation is necessary for optimal growth. There’s no need to reinvent the wheel when it comes to considering how to move to manufacturing automation. Engage an expert with experience in customizing real-world solutions for real-world pain points. As you consider your growth plans, please help us. ELSNER has helped solve hundreds of problems over the years. And he remembers that if you’re NOT automating, it could cost you in the long run.

ELSNER has earned a worldwide reputation for manufacturing automated and robotic converting machines and production lines for a wide range of industries, including paper, film, disposable medical non-woven products, filtration and wipe manufacturing. Our specialty is the design and engineering of complex and customized machinery that eliminates manual processes. As we continue to address the challenges of work, supply chain, and COVID, there has never been a time when you highlight more clearly what NOT investing in automated solutions costs you. Contact us for YOUR automated solution.

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Content sponsored by Elsner Engineering

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