How to Save Money When Buying Automatic Production line

CEO of Priority Software, a leading ERP solutions vendor with offices in Israel, US, UK, and Belgium and customers in over 40 countries. 

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No matter what they churn out at the end of the line, manufacturers are always searching for ways to lower costs and accelerate production without sacrificing quality. It all comes down to automation — automated manufacturing processes that use intelligent machines on the factory floor to fuel operational processes with minimal human intervention.

Fast forward to today’s "new normal." We're in the midst of a crisis that nobody expected, with manufacturers now having to rethink their operations, focus on remote working and adapt their processes and their workforce to regain and maintain business continuity. This has prompted manufacturers across all industry sectors to automate some or all of their workflows, while others are turning their attention to integrating automated processes into their company’s business management system to either save money, make money or both.

If your manufacturing business has already jumped on the automation bandwagon, here are five reasons you may want to consider linking your processes to your business management system:

1. Bid farewell to data silos.

Automation helps defuse conventional data silos, whereby only one group in your organization can access a set or source of data. When employees in one group are obliged to wait for tasks to be completed by those in another or search endlessly through data sources to find the right information to complete a task, their productivity wanes or grinds to a halt.

An enterprise resource planning (ERP) system automates routine business processes and stores data in a centralized location, not only making the data readily accessible to users who need it, but also enabling automated communication between teams, departments, and multisite or multinational companies. When you take this to your factory floor, you can save valuable time, resources and money by giving employees more time to do their jobs, instead of line managers having to hunt tirelessly for data.

2. Get smart. 

Incorporating new technologies, such as artificial intelligence (AI) and the internet of things (IoT), into your manufacturing processes can help you achieve smarter workflows (i.e., deeper, more unified control of your processes). 

With AI-enabled ERP, you can automate higher-level tasks beyond your daily, repetitive tasks, as the software consistently learns and becomes more adaptable. AI-enabled ERP lets you onboard intelligent tools like machine learning and natural-language interfaces that deliver actionable data insights.

Fast-emerging IoT-enabled ERP tools can help reduce product failure rates through the early detection of a problem or glitch in your manufacturing process. ERP, coupled with smart technologies, helps reduce operating and system maintenance costs, mitigate risk, increase system uptime and accelerate the design-to-manufacturing process.

3. Goodwill to all.

If you’re a manufacturer, labor is almost certainly your No. 1 expense — and the toughest to control. In the manufacturing sector, automated equipment and processes continue to replace employees on assembly line tasks, such as picking and moving parts, inspection, marking, and packaging. Not only are labor costs mitigated through automation, but automated processes also lead to tighter process control.

According to an article on TimesJobs, automated processes will essentially allow greater output for the same level of manual input. When employees’ workloads are reduced, they can focus on tasks that machines can't handle and use their time more effectively, which saves on labor costs. When processes are integrated into an ERP’s project management module, for example, you can automate forecasting, planning and the allocation of manpower and gain control of required versus actual work hours to save further labor expenses.

4. In support of planet earth.

Automated processes help reduce lost or misplaced materials and minimize expiration or spoilage of inventory, such as pharma or food products, to ultimately reduce waste. Automated processes also reduce scrap and rework because repetitive workflows tend to result in fewer failed projects and less trashing of raw materials.

Today, more than ever, manufacturers are onboarding automation to support more sustainable practices. Lights out manufacturing, for example, is a concept where a manufacturing plant is idle at night, with fully automated equipment and machines running but without a full team on site. When powered by an ERP manufacturing module, this scenario translates into substantial energy savings (e.g., lighting, heating, ventilation and air conditioning costs).

Not to mention, automation eliminates paper. With automated document management integrated into an ERP system, you can send data, attachments, images and more directly to your shop floor. Gone are the days of line managers wasting time tracking down drawings, purchase orders or packing sheets. Beyond valuable time savings, you are helping to facilitate a paperless industry.

5. The end of the line.

As a manufacturer, you want to enhance product quality, not only at the end of the line, but throughout the design-to-production process. By automating your quality assurance (QA) procedures, you can improve overall quality and reduce production costs, as well as streamline management of rework, rejects and scrap. You can also reduce the time it takes to generate and implement engineering change notices (ECNs) by controlling part revisions and inaccuracies via your ERP system, with real-time, up-to-date business data readily accessible from a single platform.

With quality processes integrated into your ERP, you can benefit from real-time monitoring and tracking at every stage in your production workflow, expediting response time. Where the "end of the line" is key, automating your quality processes can help you deliver superior end products on time and on budget.

Implementing automation in your manufacturing process is never a quick fix; it’s a continual process where your business evolves with fast-changing economies, technologies and customer demands — not to mention a sizable investment in software and machinery. For this reason, automation must be aligned with your long-term business goals in order to save money and make money.

When backed by a reliable business management system, your newly automated workflows can do both, with benefits such as fewer routine errors, less duplicated data and enhanced collaboration, from the input of raw materials at the start of the line to the finished product.

Many companies still rely on manual packaging lines in today’s business world. While this might seem like a familiar and cost-effective option, it can hold you back in the competition.

Are you interested in learning more about Automatic Production line? Contact us today to secure an expert consultation!

What if you could pack your products faster, with fewer mistakes, and even save money in the long run?

Yes, that’s possible!

By upgrading your packaging line to automatic packaging machinery. With this packaging process, you can unlock a surprising range of benefits that can significantly boost your bottom line.

Let’s explore how upgrading can transform your production line, saving you time, money, and efforts.

The High Cost of Manual Packaging

Sticking with a manual packaging line might feel comfortable, but it can silently drain your profits. 

Here’s a breakdown of the hidden costs associated with manual packaging:

• Labor Costs: Salaries, benefits, and overtime pay for your packaging team are ongoing expenses. As your business grows, so will your labor cost.
• Training Costs: Investing time and resources into training new employees for manual packaging adds to the overall cost. There is also the risk of mistakes during the learning curve, leading to wasted materials and rework.
• Inconsistency and Errors: Manual packaging is prone to human error. Missed product counts, damaged goods from improper handling, and the need for rework due to inconsistencies can cost you dearly lost products and customer satisfaction.
• Limited Scalability: Manual packaging lines struggle to keep pace with sudden surges in demand. Adding more staff can be a logistical nightmare, and inefficiencies often increase as production volume grows.

The Efficiency Revolution: How Automatic Packaging Saves Money?

What if your packaging line runs like a well-oiled machine? Automatic packaging machinery precisely does it, addressing the limitations of manual lines, and unlocking a treasure trove of cost savings. 

Let’s see how:

• Increased Speed and Throughput: Manual packaging simply can’t compete with the speed of automation. Automatic machines operate at high speeds, processing products much faster, allowing you to meet higher production demands and get your products out the door quicker.

• Improved Accuracy and Consistency: Say goodbye to missed product counts and inconsistent packaging. Automatic machines utilize precise sensors and controls to ensure every package is filled, sealed, and labeled perfectly. This minimizes errors, reduces waste, and guarantees a consistent, professional presentation for your brand.

For example, automatic filling machines can dispense the exact amount of product into each container, eliminating overfills or underfills that can cost you additional money. 

• Minimizes Labor Expenditure: One of the most significant advantages of automation is the minimal reliance on manual labor. Automatic machines can handle a substantial portion of the packaging process, freeing up staff for other tasks or allowing you to operate with a more minor team. This helps in saving salaries, benefits, and overtime pay. 

• Enhanced Safety: Repetitive tasks and heavy lifting associated with manual packaging can pose safety risks for your employees. Automatic systems built by packaging equipment manufacturers can handle these physically demanding tasks, reducing the risk of workplace injuries, and improving overall safety in your production environment. 

For instance, automatic case packers can lift and stack heavy boxes, eliminating the risk of back injuries for your staff.

These are just a few examples, but the benefits extend further. Automatic labeling machines ensure accurate product information and branding, while automatic palletizers efficiently stack and secure products for shipping, minimizing damage, and saving on transportation costs.

Beyond Efficiency: Additional Benefits of Automation

While the efficiency gains from automatic packaging are impressive, the advantages extend even further. Here’s how automation can provide a holistic boost to your production line:

• Minimizes Waste Material: Manual packaging can lead to excessive waste materials due to overfills, inaccurate measurements, or damaged products during handling. With their precise controls and sensors, automatic systems can optimize material usage, minimizing waste, and saving you money on packaging materials. 

For example, automatic bagging machines can measure products precisely and create perfectly sized bags, eliminating excess packaging, and reducing material costs.

• Improves Product Quality Control: Ensuring consistent quality is crucial for customer satisfaction and brand reputation. 

Automatic machinery can integrate seamlessly with quality control systems such as 

• Vision inspection systems can detect product defects or inconsistencies.
• While automatic sealing systems ensure tamper-proof and leak-proof packaging, enhancing product quality.

• Increased Flexibility and Scalability: Automatic packaging lines are not one-size-fits-all. Modern machines offer a high degree of flexibility, allowing you to handle a broader range of product sizes, shapes, and packaging formats. This adaptability is crucial for businesses that offer a diverse product line or anticipate future growth. 

Additionally, automatic lines can quickly scale up or down based on production demands, helping you adapt to fluctuations in customer needs without significant disruptions.

• Integration with Existing Systems: Modern automatic machinery isn’t isolated equipment. You can integrate it with your existing production management software. This allows for real-time data collection, machine performance monitoring, and integration of inventory management systems. This improved data analysis and control can further optimize your entire packaging process. 

Making the Smart Choice: Considerations Before Upgrading

While automatic packaging machinery offers many benefits, it’s essential to acknowledge that the upfront costs can be significant. However, the long-term savings and efficiency gains can often outweigh the initial investment. 

Here’s a step-by-step guide to help you make an informed decision:

• Conduct a Cost-Benefit Analysis: The first step is identifying your pain points with manual packaging. Calculate the ongoing costs associated with labor, training, rework due to errors, and wasted materials. Then, research the potential cost savings that automation can bring regarding increased production speed, reduced waste, and lower labor needs.
• Assess Production Needs: Carefully evaluate your specific production requirements. Consider factors like the speed you need to meet current and future demand, the capacity of the equipment, and the compatibility with your existing product types, and packaging formats.
• Research Different Equipment Options: Don’t jump on the first machine you see! Research different automatic packaging machinery manufacturers and compare features, functionalities, and costs. Look for equipment that aligns with your production needs and budget.
• Consider Space and Integration: Ensure you have the physical space to accommodate the new machinery on your production floor. Evaluate if the equipment can integrate seamlessly with your existing lines or if additional modifications might be necessary.

Conclusion

By now, it’s clear that upgrading to automatic packaging machinery isn’t just about convenience; it’s a strategic investment in the future of your business.

Now, you might consider where to customize or purchase the best machinery for your business.

Accutek Packaging Equipment Companies is the trusted partner as packaging machinery manufacturers and leader in providing the best packaging equipment for your industry.

Accutek is a packaging equipment manufacturer that offers a comprehensive range of high-quality, reliable automatic packaging machinery solutions. Our experienced team can help you assess your needs, recommend the ideal equipment for your production line, and ensure a seamless integration process.

Ready to unlock the true potential of your packaging line? 

Visit us today to explore our extensive product portfolio and speak with a packaging specialist. 

For more information, please visit High Efficiency Double Head CNC Lathe.