5 Trends in Manufacturing Process Optimization for Small Manufacturing Shops
Automation and Digitalization: Making Work Easier and Faster
Small and mid-size manufacturing shops face unique challenges in keeping their operations efficient and competitive. Adopting the latest trends in process optimization can help them stay up to date for their customers by simplifying operations, improving efficiency, and ultimately increasing profitability – which can be reinvested in additional capability. Here are five manufacturing process optimization trends in 2024 that can significantly impact the shop's performance.
Automation
Automation is not only for large-scale manufacturing sites. Increasingly affordable technologies and expert integration partners are enabling small manufacturing shops to increase their degree of automation. They can handle repetitive tasks more efficiently by integrating robotic process automation (RPA) or programmable logic controllers (PLC). This capability allows your team to focus on more complex tasks, reducing the chances of human error and speeding up production. When adding automation, it is important to dedicate staff to cover all pertinent roles and responsibilities.
Digitalization
Digitalization is another emerging trend in optimizing your manufacturing process. Digital tools help collect an increasing amount of data. This information is critical to baseline the current state of operations to identify improvement opportunities.
Adding more digital tools and data acquisition sensors and equipment also enhances communication and provides data in real time, allowing operations leaders to make more informed decisions faster. In addition, implementing Manufacturing Execution Systems (MES) software and connecting systems that produce the data IoT can enable predictive maintenance and optimize asset operation for the entire shop floor.
Practical Applications
One potential application is a small metal fabrication shop using digital twins—a numerical model that simulates its physical-asset counterpart—to simulate different production scenarios. The physical asset collects data to feed to the model, which simulates and optimizes workflows virtually. Then, when the shop team adds optimizations to the physical assets, the performance can improve quickly based on the data analysis.
Another application could be for an electronics manufacturer to implement RPA to automate assembly tasks, leading to quicker turnaround times and better product quality.
Energy Management: Saving Costs While Going Green/Energy Audits
Energy management is vital for reducing operational costs and promoting sustainability. Conducting energy audits identifies areas where your shop wastes energy (such as compressed air and steam leaks) and suggests improvements. Simple changes can make a big difference, such as upgrading the facility to energy-efficient LED lighting or modern, high-efficiency heating, ventilation, and air conditioning (HVAC) systems.
Creating a Pareto analysis of energy-consuming processes teaches shop leaders which steps contribute the most to process improvement options.
Sustainable Practices
In addition to cost savings, sustainable practices are becoming increasingly important to customers and regulators. Small manufacturing shops can reduce their environmental impact and appeal to eco-conscious consumers by investing in energy-efficient machinery and renewable energy sources.
Two added benefits to adopting sustainable practices are the natural cost reduction that comes from energy and material reduction and the opportunity to realize tax credits and incentives for more sustainable options.
Practical Examples
Air and steam leaks are critical indicators of an inefficient system or process. Conducting an energy audit identifies how focusing on process optimization can deliver both cost and sustainability gains. Some techniques Turner Process uses are:
Inspecting for leaks
Adjusting pressure settings
Analyzing energy consumption
Through these analyses, the audit identifies process inefficiencies. For instance, addressing over-pressurization or using variable-speed drives can align compressor capacity with demand, reducing energy waste. Longer-term, upgrading to more efficient systems, fixing leaks, and instituting regular and preventative maintenance can lead to lower operational costs and improved efficiency.
Another example of process improvement through energy audits is identifying steam leaks. Regularly inspecting steam systems for leaks and repairing faulty valves or piping can lead to significant energy savings. A thorough audit can highlight where excess heat is being lost or energy is wasted. Tactical improvements like:
Enhancing the k-factor of pipe insulation
Upgrading to more efficient steam systems or material grades more resistant to aqueous corrosion
Reducing routing lengths of steam pipes through the facility to limit heat and pressure loss
Reducing the number of joints in steam routing as potential leak sources
These modifications can improve system efficiency, reduce costs, and minimize environmental impact and elevate system performance and process efficiency.
System Upgrades: Staying Current with Technology…Why Upgrade PLC Systems?
Programmable logic controllers (PLC) are central to many manufacturing processes. However, outdated systems can lead to inefficiencies, more frequent downtime, and higher maintenance costs. Regularly upgrading PLC systems helps keep production lines at small shops efficient and compatible with new technologies.
Preparing for the Future
Upgrading systems is not just about keeping up with trends—it's about preparing your shop for future challenges ("future-proofing"). Investing in scalable and flexible technology ensures that your shop can adapt to changes in demand and maintain competitiveness in a digital world.
PLCs are the nervous system of shop equipment, connecting the controller with sensors and actuators to help the shop equipment communicate effectively. Upgrading PLCs ensures a small shop can adopt modern, more complex inputs from machine vision or automatic positioning systems.
PLCs also enable distributed control, adding multiple control loops throughout the shop vs. having one central control.
Application Opportunity
A small food processing company using an old PLC system monitors production remotely by upgrading to a modern, internet-connected PLC. By adding remote tank levels or grain bin sensors, inventory accounting accuracy improves, reducing over-purchase and reducing waste generated by excess material.
Continuous Process Improvement: Lean and Six Sigma/Lean Manufacturing
Lean manufacturing focuses on reducing waste and increasing productivity. Small shops can streamline operations and cut costs by identifying and eliminating non-value-added activities. Implementing lean practices such as 5S (Sort, Set in Order, Shine, Standardize, Sustain) and Kaizen (continuous improvement) can result in significant efficiency gains. Small shops are executing Lean Sprints to quickly identify and take action on implementing waste-reduction steps.
Six Sigma
Six Sigma uses data-driven methods to reduce defects and variability in manufacturing processes. By applying Six Sigma principles, small shops can improve product quality, reduce waste, and increase customer satisfaction through reduced costs while maintaining product performance.
Practical Applications
One application could be a small automotive parts manufacturer using Lean principles to reorganize their workspace, making it easier for workers to find tools and increasing productivity. Another is an industrial paint producer implementing Six Sigma to improve their powder coating process by optimizing color distribution for a more even coat, producing more consistent colors and less rework/waste of the paint material.
Building Automation: Smart Facilities for Better Control/Implementing Building Automation Systems (BAS)
Building automation systems (BAS) are now within reach for small manufacturing shops. BAS can control lighting, HVAC, security, and other building systems, leading to enhanced safety and significant energy savings. They create centralized networks of hardware and software to monitor a building.
Benefits of a Smart Facility
A smart manufacturing facility isn't just efficient—it's adaptable. BAS can provide real-time data on energy use, equipment status, and environmental conditions like air quality, helping small shop owners maximize uptime in their facility.
Smart Automation Practical Examples
An electronics assembly shop might use BAS to control its cleanroom environment automatically, ensuring optimal conditions for production while reducing energy costs. A small brewery could also use BAS to monitor and control fermentation, ensuring consistent product quality.
Strategies for Manufacturing Excellence and Future-Readiness
Optimizing your manufacturing process is essential for maintaining competitiveness, reducing costs, and improving product quality. By adopting trends like automation, energy management, system upgrades, continuous improvement, and building automation, small manufacturing shops can proactively equip their facilities for long-term success and prepare for their customers' evolving needs.
📞: Contact Turner Process Process today for expert advice on any process optimization task and options for operating leases to let you automate today.
