How to Optimize Processes with a Manufacturing System

In the world of production, manufacturing systems are fundamental to evolution and efficiency. Every minute wasted and every resource misused represents a potential loss of competitiveness.

In this context, process optimization emerges as a new form of modern manufacturing.

It lies in the intelligent implementation of manufacturing systems, technology, strategy and management that promises not only to maximize efficiency, but also to transform the way production is conceived and executed.

In this article, we will look at how manufacturing systems can unleash the latent potential in manufacturing processes and operations boosting the competitiveness and profitability of companies in an increasingly demanding and dynamic marketplace.

What is manufacturing process optimization?

Manufacturing process optimization is a systematic approach to improving the efficiency, quality and profitability of a company's production operations. It involves identifying, analyzing and continuously improving each stage of the manufacturing process to eliminate waste, reduce cycle times, minimize costs and maximize productivity.

This process can involve a variety of strategies and techniques, ranging from reorganizing the physical layout of the plant to implementing advanced technologies such as automation and real-time data analysis.

Some of the key areas of focus are production planning and scheduling, inventory management, supply chain optimization, quality improvement and personnel training.

There are different types of manufacturing systems and these depend on the product, customer and production era the company is in.

• Make to order
• Make to stock
• Assemble to order
• Engineer to order

How to optimize processes with a manufacturing system

Optimizing production processes, efficiency and quality is achieved by implementing new advanced technologies that are not so complex.

With this arises the new trend in the manufacturing industry called Lean 4.0, which represents an extension of the Lean management approach.

The 4.0 signals an evolution towards the Industry 4.0 era, in which digital technologies and connectivity play a crucial role in optimizing manufacturing processes.

Let's look at some of the ways in which this new manufacturing system helps to optimize processes: 

Mass hyper-customization

It is about meeting all customer expectations and specific needs at a scale that is associated with mass production. The Lean 4.0 manufacturing system seeks to combine the efficiency and agile solution of large-scale manufacturing with detailed customization. 

Platform operating model  

An approach to production organization and management that stands out for its flexibility, modularity and scalability, as it makes use of advanced technological platforms. 

Cloud computing

It is a model in the manufacturing system of provision and access to services that facilitates the storage, management and processing of data and applications on remote servers. It allows access through internet connection instead of relying on local resources.

IIot Industrial Internet of Things

It is an extension of the Internet of Things to the industrial and manufacturing environment and involves the interconnection of devices, sensors, machinery and systems in industrial environments. This facilitates the collection, exchange and analysis of data in real time thus optimizing processes.

This new manufacturing system model is crucial in industry as it provides tools to improve efficiency in monitoring and control, increase productivity, implement predictive maintenance strategies to reduce costs and perform advanced data analysis to make more informed decisions in real time. 

Big Data and analytics

These are excessively large and complex data sets that are beyond the capacity of traditional software tools to manage, analyze and process.

Analytics refers to the process of examining this data to identify patterns, trends, correlations or important information to facilitate decision making.

With these new manufacturing systems technologies, companies can understand and process volumes of this caliber of data and improve efficiency, predictive maintenance, cost reduction and much more. 

Artificial intelligence 

This is the ability of machines and computer systems to mimic and perform tasks that would require a human. These also include machine learning, natural language processing, and data-driven decision making.

Automation and Robotics 

“Autonomous Systems and Robots” refers to the use of automated systems and robots that serve to perform tasks and processes autonomously, without the need for direct human intervention.

This manufacturing system trend is essential for factors such as: efficiency improvement, error reduction, long-term cost reduction, labor safety, flexibility and adaptability, and integration with emerging technologies. 

Augmented reality

This manufacturing system technology superimposes digital information such as graphics, images and data on the physical environment in real time.

It helps optimize processes for reasons such as: training and educating personnel, assisting in production, maintenance and repair, design and prototyping, improving productivity by having access to accurate information in the work environment, and solving problems in real time.

Cybersecurity 

Practices designed to protect computer systems, networks, devices and data against threats, cyber attacks, etc. 

Digital twin 

This manufacturing system trend is an accurate virtual representation of a product, process or physical system in real time. It reflects all aspects and behaviors of the real-world object or process, allowing its performance to be simulated, analyzed and predicted.

It is useful for the manufacturing industry because it helps to perform simulations and optimizations in a test environment, forecast maintenance requirements, facilitate product design and development, analyze information in real time, streamline product customization, and reduce risks and costs.

Additive manufacturing

Also known as 3D printing, it is a construction process that creates three-dimensional objects layer by layer from powder, liquid or filament material.

With this technology, companies can create complex components from digital data without using specific tools or molds. With additive manufacturing, they can optimize costs, material time and more. 

Customer experience 

Customer experience is also a crucial part of the manufacturing industry, as companies seek to not only manufacture high-quality products, but also provide a positive, personalized and satisfying experience to their customers throughout their interaction with the brand.

Digital OEE

Overall Equipment Efficiency (OEE) is a metric in the manufacturing system that serves to measure and evaluate the overall efficiency of a piece of equipment, a production line or a plant.

This metric represents the percentage of actual productive time that is optimally utilized compared to the total available, considering availability, throughput and quality times.

Transformation cycles

The manufacturing industry is evolving from long cycles to more agile and flexible ones. Technology models such as 3D printing and data analytics are now being used to help streamline development. 

Focus on ESG (Environmental Social Governance)

This approach to the manufacturing system involves the integration of environmental, social and corporate governance aspects into business operations and seeks to adopt sustainable practices.

Sustainable circular economy 

Promotes sustainability by optimizing efficiency throughout the life cycle, thereby reducing waste and costs by reducing the carbon footprint and associated processes of manufactured products.

It also makes use of AI and machine learning to improve processes, optimize operations and obtain real-time information.

Off-shoring strategies 

This strategy of the 4.0 model of the manufacturing system allows companies to reduce costs by seeking cheaper labor from different countries. 

Near-shoring strategies 

It has greater agility in delivery because it involves the relocation of operations closer to the consumer market. Also, a better response to demand and efficient communication between the actors in the chain. 

Implement a manufacturing system with London Consulting Group

While other companies focus solely on selling technology, London Consulting Group excels at efficiently applying existing technology, thus maximizing the investment made in the plant.

Our approach is distinguished by offering a comprehensive implementation, which includes not only the installation of tools, but also the training of employees to ensure effective adoption.

In addition, we stand out for offering customized development, adapting processes to the specific needs of each client, beyond simply implementing standard solutions.

Contact us to implement an efficient and optimal manufacturing system for the changes of these times.