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Machine performance in a production facility - a practical guide
Estimated reading time: approx. 10 minutes
TL;DR
- Machine performance directly influences the timeliness of deliveries and the quality of products
- Implementation new technologies and automation eliminates downtime and reduces errors
- Diagnosis of indicators (e.g. OEE) allows key areas for improvement to be identified
- Reducing changeover times and robotisation is a fast way to increase efficiency
- Investments in organisation and staff result in a stable increase in production efficiency
Table of contents
- Introduction
- Why machine performance is key
- Diagnosis of machine performance problems
- Methods for improving machine performance in practice
- The role of people in improving machine performance
- Implementing robotisation as a strategic step to increase productivity
- How to assess the cost-effectiveness of investments in improving machine performance
- Summary of conclusions and recommendations
- FAQ
Introduction
In today's competitive manufacturing industry, machine performance plays a key role in maintaining a high market position. Companies are constantly looking for ways to increase work rates, improve quality and reduce costs at the same time. In this article, I explain how machine productivity can be effectively improved with the right technological and organisational solutions. After reading, you will learn how to diagnose productivity problems, how to implement automation and which solutions to use to achieve sustainable efficiency gains.
Why machine performance is key
Machine productivity translates directly into a company's ability to scale production, on-time delivery of orders and the quality of finished products. In the reality of rising customer expectations and intensifying competition, any delay in processes can have an adverse impact on the final bottom line. It is therefore worth taking special care with efficiency levels and avoiding costly downtime.
Effects of poor machine performance
Low machine productivity often manifests itself in a drop in production volumes, increased waste and rising costs associated with potential repairs and employee overtime. As a result, the company loses fluidity in order fulfilment, which can result in reduced competitiveness and customer retention problems.
It also happens that insufficient machine efficiency forces the company to make additional work shifts, expand the team or order expensive spare parts. All of this translates into fixed costs that, in the long term, can limit business growth.
New technologies and efficiency gains
In the era of Industry 4.0, we have a number of modern solutions at our disposal, such as vision systems, integrated controllers or collaborative robots (cobots). Their implementation eliminates downtime, speeds up repetitive operations and reduces human error. This directly improves machine performance and, in turn, allows orders to be completed faster while maintaining high product quality.
Diagnosis of machine performance problems
Before making changes, a sound analysis of the sources of losses and errors occurring in the production cycle is essential. This allows us to accurately assess which areas need the most improvement and how the machinery fleet should be improved.
Key performance indicators
The basis for comprehensive diagnosis is the monitoring of indicators such as Overall Equipment Effectiveness (OEE), Cycle Time or Downtime Rate. They make it possible to determine precisely how much time a machine is actually running and what proportion of that time is used optimally.
The data collected allows further questions to be identified:
- Are there reserves in the organisation of work?
- How often does the machine go into breakdown or maintenance?
- Are the interruptions mainly due to technical problems or shortcomings in the flow of material?
The most common causes of lost productivity
In a large number of production facilities, the main reasons for poor machine performance are breakdowns and technical downtime. Insufficient operator skills and a lack of process standardisation also play an important role. In addition, outdated control systems, non-ergonomic workstations and long changeover times mean that the production rhythm is sometimes unstable.
Some companies face problems in the storage and distribution of components. If raw materials are not delivered at the right time, the machine cannot run at full capacity, which immediately affects production statistics. This is why it is important to analyse internal logistics in terms of their compatibility with the performance of specific machines.
Bottleneck analysis
The concept of bottlenecks is also proving helpful in improving machine performance. It consists of identifying the process that slows down the flow of material the most and then implementing solutions to reduce the effects of this bottleneck. This could be replacing equipment with more advanced machines, modifying the production process or extending automation by adding robots to perform the most demanding stages.
Methods for improving machine performance in practice
Once a detailed diagnosis has been made, an action plan should be developed to increase efficiency. Depending on what problem the company is facing (e.g. excessively long changeovers, unpredictable downtime, lack of qualified staff), different tools and strategies are used.
Modernisation and adaptation of the machinery fleet
A key step towards higher efficiency is sometimes to upgrade old equipment and equip it with advanced control systems and sensors. This allows better control of operating parameters and avoids unplanned failures. Regular maintenance and service can reduce costly downtime and ensure stable operating conditions.
It is worth backing this up with the support of professional companies that offer service and maintenance of robotic workstations. An example is the offer Service and maintenance stands - a service that keeps machines and robots in excellent technical condition.
Reducing changeover times
Extended changeover times are a frequent challenge, especially in companies that frequently change their production mix. Extended changeovers reduce machine availability and limit the possible production volume in a given period. One of the most effective methods for reducing changeovers is to implement the SMED (Single Minute Exchange of Die) technique. Its aim is to reduce the number of steps carried out when a machine is switched off, and to standardise the individual steps so that the service team can operate efficiently according to strictly defined procedures.
Using robots for repetitive tasks
Repetitive and time-consuming activities such as packaging, palletising or loading workpieces into machine tools can be fully automated using robots. This has a positive effect on extending the line's operating times (24/7 mode) and maintaining a high process tempo.
In practice, for example, industrial robots or cobots are used to effectively relieve people from monotonous and physically taxing tasks. Michale Automatika offers full support for the robotisation of production processes, resulting in a visible increase in productivity while reducing costs. For more information, you can visit Robotics - an offer from Michale Automation.
Standardisation and visualisation of processes
Thanks to the standardisation of processes, every operator knows exactly when and how to carry out the various activities. Properly prepared instructions, pictograms and monitoring systems minimise the risk of human error, leading to a significant reduction in unplanned downtime.
In the case of complex machines belonging to different departments of a company, visualisation that allows parameters (e.g. temperature, speed, vibration) to be tracked in real time is also useful. This, in turn, facilitates early detection of abnormalities before downtime even occurs.
Automation of areas difficult to control
If a company is facing a shortage of staff or frequent human errors, it is worth thinking about automating processes such as welding or grinding. When modern robots are used, a high degree of parameter repeatability is ensured, which increases both productivity and the quality of the finished product.
Depending on the specifics of production and the level of workload on the workforce, consideration may be given to:
- Deployment of welding robots with real-time monitoring of weld quality.
- Packaging and palletising solutions, available from robotisation of packaging.
The role of people in improving machine performance
Despite increasing automation, humans still have an important role to play in maintaining and developing machinery. A close-knit team of specialists and operators, who know the strengths and weaknesses of the equipment, will operate much more efficiently than a group of randomly selected employees.
Training and competence development
Trained operators are quicker to react to signs of a malfunctioning machine, thus avoiding breakdowns. They also know when and how to carry out minor adjustments or replace basic components so that the line does not come to a standstill for several hours.
In the long term, the company benefits from the investment in staff knowledge also because it facilitates adaptation to new technologies such as collaborative robots or vision systems. In typical production processes, there is no shortage of places where a skilful human eye and experience are irreplaceable - especially when unusual events occur or quick corrections need to be made.
Motivation and cooperation
An often underestimated factor affecting the productivity of machines is the motivation of the people who work on them. A close-knit team shows a higher level of responsibility and care to ensure that equipment is fully operational. A good flow of information between operators and the maintenance department enables minor faults to be rectified more quickly and facilitates the optimisation of resource utilisation.
Implementing robotisation as a strategic step to increase productivity
Against the backdrop of increasing market demands and labour cost constraints, robotisation is becoming a welcome solution in large factories as well as medium or small industrial plants. Michale Automatika, being an official distributor of SIASUN robots, provides turnkey projects - from process analysis to implementation to servicing.
Advantages of automation and robotisation
- Increased efficiency: The robots can operate continuously 24/7, eliminating the interruptions inherent in human shifts.
- Fewer faults: The precise movements of the programmed robot arms mean that the risk of errors in repetitive tasks is drastically reduced.
- Faster lead times: The higher productivity of the machine allows more orders to be handled in a shorter time, enabling the company to better respond to market demands.
- Scalability: Once the first robot has been implemented, it is easier to integrate further equipment, adapting to changes in product range or production volume.
Example of robotisation of repetitive tasks
One of the common problems in many companies is the production of a series of products requiring identical, repetitive operations. Thanks to solutions such as robotisation of repetitive production downtime and errors can be minimised, resulting in stable quality and predictable results.
The robot can cope with jobs involving high precision or monotony, while operators can focus on tasks requiring technical inspection, visual assessment or ongoing production decisions. This significantly improves team morale and affects the efficient use of human resources.
How to assess the cost-effectiveness of investments in improving machine performance
The decision to increase the productivity of machinery always implies a certain cost - whether it is related to upgrading, implementing robots or hiring additional specialists. To avoid disappointment, it is worth estimating the return on investment (ROI) even before the project starts.
Cost and profit analysis
When estimating ROI we take into account:
- Cost of purchasing or upgrading equipment (including potential integration and training costs).
- Savings brought about by higher efficiency (reduced cycle times, fewer defective products, reduced overtime).
- Increased production volumes and the ability to fulfil more orders.
Tools to help assess ROI
Many companies are now using dedicated calculators for the effectiveness of industrial robot deployments. These allow a number of factors to be taken into account, such as the cost of purchase, potential subsidies, robot uptime, potential reductions in scrap, as well as the projected increase in revenue resulting from the increased productivity of the machine. One example of such solutions is ROI calculator welding robotisation - although it concerns a specific welding process, it can be taken as a certain reference for other applications.
Summary of conclusions and recommendations
- Regular analysis of performance indicators (e.g. OEE and Downtime Rate) is the basis for informed machine performance management.
- Upgrading machines and equipping them with modern control systems reduces downtime and repair costs.
- Techniques for reducing changeover times (e.g. SMED) help to optimise the use of resources and respond quickly to changes in the product range.
- The robotisation of repetitive processes, such as packaging or welding, leads to a noticeable increase in productivity.
- Training operators and keeping the team motivated contributes to the elimination of breakdowns and more efficient use of equipment.
- The assessment of the profitability of potential investments should take into account both the purchase costs and any savings resulting from reduced cycle times or a reduction in the number of shortages.
Improving a machine's performance requires a comprehensive approach - from diagnosing the current situation, to upgrading equipment and training operators, to selecting the right automation solutions. By preparing a detailed plan and working with an experienced partner, many risks can be eliminated and the expected benefits accelerated.
It is therefore a good idea to start by auditing your existing machinery, prioritising and gradually implementing improvements. If you are interested in improving productivity using robotisation or want to see how your company can optimise its production, visit Michale Automation and familiarise yourself with the opportunities available. With innovative solutions and the support of specialists, your company can quickly gain a competitive edge and the changes implemented will consolidate stable growth for years to come.
I encourage you to comment on the article and share your experiences of fleet modernisation implementations. You can also sign up to the newsletter to receive notifications of new publications and industry tips. Share this text on social media if you think it might be helpful to other manufacturing business owners or managers.
Thank you for your time and good luck in implementing changes to improve the efficiency of the machines in your production facility!
FAQ
How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.
Does automation mean redundancies?
As a rule, no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies are using this to retrain and develop the team professionally.
Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.
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