Manufacturers of consumer goods are encountering higher consumer expectations than ever before and are turning to industrial automation to help them rise to the challenge of these demands. Consumers today are generally more discerning and have higher expectations compared to previous generations. Modern consumers, especially younger generations like Gen Z, are more deliberate about their purchases. With easy access to product reviews and comparisons, they are more informed and have higher standards for product quality. Additionally, they have many competing choices for any number of products and often gravitate toward buying the option most suited to their preferences. The rise of digital technology has conditioned consumers to expect instant gratification in all aspects of their lives, not just during the time they spend behind a screen—translating to demand for rapid product fulfillment and speedy delivery.
As high consumer expectations have put new pressure on manufacturers to produce a variety of quality products quickly, industrial automation offers multiple solutions for superior-quality, high-mix products fast.
Industrial Automation Delivers High-Quality Standards
Robots and industrial automation play a crucial role in achieving high-quality products thanks to their ability to perform tasks with perfect repeatability. Because robots are programmed to follow exact application parameters, they eliminate human error by consistently performing each task accurately. Industrial robots handle parts in the same way during each cycle, which minimizes variations and defects.
Furthermore, automated inspection systems using machine vision, such as cameras and sensors, ensure quality. Cameras capture analyzed images and videos to identify deviations from the standard. Automated systems use computer counting to count parts and products to guarantee accuracy. Sensors are placed on machinery and production lines to monitor various parameters such as temperature, pressure, and vibration of equipment. Supervisory Control and Data Acquisition (SCADA) systems collect real-time data from sensors and devices across the manufacturing floor to monitor proper operation.
By leveraging these technologies and processes, automation systems enable manufacturers to collect and analyze data effectively, leading to improved decision-making, enhanced quality control, and increased operational efficiency.
Flexible Manufacturing Caters to Variety in Production Demand
With industrial automation, manufacturers are empowered to offer more personalized products without significant cost increases, enabling them to stay competitive and responsive to market changes. The ability to manufacture multiple SKUs (Stock Keeping Units) on the same product assembly line offers several advantages for manufacturers.
Manufacturing multiple SKUs on the same line means manufacturers can quickly adapt to changing consumer demands without significant downtime. This flexibility allows them to offer a wider range of products tailored to individual preferences. Manufacturers can reduce the costs associated with setting up and maintaining separate production lines by using the same assembly line for multiple SKUs. This efficiency can lead to lower production costs and more competitive pricing. This capability supports the production of customized products, meeting the growing consumer demand for personalized items. It allows manufacturers to offer a variety of options without compromising on efficiency.
Industrial automation achieves the production of multiple SKUs on the same assembly line through several advanced technologies and processes. In particular, Programmable Logic Controllers (PLCs) can be programmed to control different aspects of the production process. They allow for quick changes in the production setup, enabling the line to switch between different SKUs without significant downtime. Additionally, quick-change tooling is particularly beneficial in flexible manufacturing environments. Quick-change tooling systems use specialized tool holders and adapters, allowing tools to be swapped out quickly and easily. The system ensures that each tool change is highly repeatable, meaning the new tool is positioned accurately every time. By significantly reducing the time needed to change tools, quick-change tooling minimizes machine downtime, ultimately making it easier and faster to produce multiple SKUs on the same line.
Satisfying the Instant Gratification Mindset with Automation Solutions
With flexible manufacturing techniques, such as quick-change tooling, come additional benefits. The ability to switch between different products on the same line means faster production cycles. This can significantly reduce lead times, ensuring that products reach consumers more quickly. Manufacturing multiple SKUs on the same line allows for more efficient inventory management. Manufacturers can produce smaller batches of each SKU, reducing the risk of overproduction and excess inventory.
Moreover, automated systems can operate around the clock, ensuring that production continues outside regular working hours. This efficiency is a great advantage in dealing with changes in demand and volume.
Lastly, reshoring leads to improved opportunities for customer satisfaction. Products are made closer to the end consumer; fewer international logistics and customs processes streamline the supply chain. Reduced transit times mean products are more readily available to sellers and buyers alike.
At Wes-Tech, we are dedicated to helping manufacturers meet and exceed the ever-evolving expectations of today’s discerning consumers. Whether you’re looking to enhance product quality, increase operational efficiency, or adapt to market changes with agility, our automation solutions are designed to support your goals.
We invite you to reach out to us to learn more about how our innovative technologies can benefit your manufacturing processes. Contact us to discuss your specific needs and discover how we can help you stay competitive in a rapidly changing market.