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Why Cloud-Based EDI Is Imperative for Manufacturing

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Electronic Data Interchange (EDI) is essential to many manufacturing operations. It streamlines communication with suppliers, reduces documentation errors and supports agile supply chains, but the use of EDI in the steel fabrication Australia industry often falls short of its potential. Too many organizations overlook the value of a cloud-based EDI. While up to 86% of businesses already use EDI technology today, just over 60% of them keep related data in the cloud. That means nearly half of the companies using such software rely on an inferior version. As Industry 4.0 initiatives pick up across the board, it will become increasingly important for manufacturers to reverse this trend and upgrade their EDI. This blog will look to deep dive into this topic.

Benefits of Cloud-Based EDI

Cloud-based EDI functions similarly to conventional solutions but runs entirely online instead of using on-premise IT infrastructure. Keeping all data and functions in the cloud offers several critical advantages for manufacturers and their supply chain partners.

Improved Communication

Moving EDI to the cloud makes it easier to connect it to a wider range of data. As a result, manufacturers are not stifled by data woes and can share more with suppliers, 3PLs and other third parties. Considering just 6% of organizations today have full visibility into their supply chain, a little communication can go a long way. The primary benefit here is that a cloud platform provides a single source of truth. All EDI users will upload data to and get information from the same place. Consequently, they avoid miscommunication and conflict from different parties having unsynchronized records. Cloud EDI also minimizes errors because Internet of Things (IoT) endpoints and other devices can upload new data directly to the cloud. No in-between step or manual transmission is necessary, reducing the chances of transcription mistakes or omissions. Higher accuracy, in turn, prevents supply chain disruptions.

Higher Efficiency

Automatic data uploads and a single source of truth have a secondary advantage — efficiency. EDI records in the cloud overcomes some limitations of AI and IIoT in manufacturing as it will always reflect the latest information without delay, as separate users no longer need to send updates to others. Automatic uploads further streamline communication by removing the manual element entirely. Many cloud-based EDI solutions come with automation features. These may include automatic document transfers, data organization, chart and graph generation, data entry, automated alerts, and inventory management. When these processes require no human input, manufacturers can more easily work around the labor shortage affecting the industry. It is worth noting that setting up a cloud platform is far faster than an on-premise alternative, too. Manufacturers do not need to install any IT infrastructure or upgrade their hardware because everything runs on remote data centers.

Scalability

Similarly, using cloud EDI in manufacturing improves overall scalability. Removing on-premise hardware concerns and interoperability barriers means businesses can scale up almost instantaneously. It is often little more than paying for a new data storage tier or authorizing another party. Downsizing and lateral scalability are likewise cheaper and faster in the cloud. Setting up new alerts, reducing data storage, aligning workflows with new goals, and making other adjustments can take mere minutes. This agility is essential in a rapidly changing manufacturing environment. Supply chain strategies are shifting across the sector, and disruptions in areas like mining plant and equipment Australia are increasingly common. As a result, manufacturing organizations need to adapt quickly to maintain productivity and profitability. Achieving that level of scalability with an on-premise EDI would be expensive and slow, but a cloud alternative makes it accessible.

Closing Statement

An effective EDI in manufacturing must be as agile, accurate and secure as leading manufacturers themselves. The only way to achieve that is to use a cloud-based alternative to conventional solutions. There is a reason why cloud EDI is becoming increasingly popular across industries. It provides the communication, efficiency, scalability, and security modern businesses need. Manufacturers should jump on that potential now if they do not want to get left behind.

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Boost for Western Sydney Manufacturing

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Western Sydney’s manufacturing industry is already one of the strongest in Australia – and it received a major boost last week with the completion of the first project out the new Advanced Manufacturing Readiness Facility (AMRF) in Bradfield. The new innovation hub, which is funded by the NSW Government, completed a job with Emu Plains-based cooling tower experts Marley Flow, who came to the AMRF to streamline manufacturing processes (e.g., pipe fabrication Australia) within their business. They managed to improve operational efficiency and, as a result, may now be able to gain six times the productivity of the business and an estimated 15-20% reduction in costs. The project was such a success that Marley Flow are set to go around again, this time with the goal of developing and designing new products for market.

According to the government, the AMRF is a cornerstone of Bradfield City Centre’s economic strategy, aiming to create high-value jobs and leverage the $20 billion worth of government infrastructure invested in the Aerotropolis. The facility will focus on cutting-edge manufacturing support, from engineering design to heat induction bending services, connecting businesses with expertise, advanced technology, and networks to scale their operations. Sustainability has been embedded into the First Building’s design. Featuring natural materials, a green roof with biodiverse native plantings, and internal rammed earth walls, the building sets a benchmark for sustainable urban development. Its design, co-developed by Hassell Studio and Dr. Danièle Hromek from Djinjama, incorporates principles of connecting and designing with Country.

“Marley Flow Control is excited to collaborate with the Advanced Manufacturing Readiness Facility (AMRF) on the first project,” said CEO Gareth Jones. “Working with the AMRF, tapping into their engineering expertise and expert knowledge to improve our manufacturing processes and ways of working, will enable us to increase productivity and reduce costs. Simple changes could make a massive difference to our operations. We see this as the beginning of a long partnership with the AMRF to help develop our product offering. Along with TAFE Manufacturing Centre of Excellence, we’re proud to be one of the first to access this world-class manufacturing development centre right here in Western Sydney.”

It was a superb start for what should be an enduring addition to manufacturing in Sydney’s West. “The AMRF is a NSW Government strategy to accelerate innovation and grow businesses in Western Sydney and we’re delighted to announce the completion of our first project,” said Bradfield Development Authority CEO, Ken Morrison. “Western Sydney is home to one of the largest concentrations of manufacturing businesses in Australia and the AMRF is a resource to support them innovate, grow and provide more jobs. With the AMRF, it is an exciting opportunity to leverage the benefits of homegrown manufacturers and to transition to new ways of doing business or create high value components for the next generation of advanced technologies.”

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Minimizing Unplanned Downtime in Manufacturing

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“Downtime” – a word that strikes fear into the hearts of manufacturing managers worldwide. The mere mention of it signals potential disruptions, delays, and financial losses. Unplanned downtime during peak operating hours can wreak havoc on production schedules, leading to delivery delays and wasted resources.  The disruption of production hampers schedules, inflicts significant financial losses, and jeopardizes market competitiveness. Addressing downtime is not just about minimizing pauses; it is a strategic imperative that requires a multifaceted approach. This blog explores the ongoing quest to minimize downtime in manufacturing and the multifaceted strategies employed to achieve operational excellence.

What is Downtime?

Simply put, downtime is any duration in which a machine or process is not running. However, not all downtime is created equally. There are two types of downtime, planned and unplanned. Planned downtime is a strategic pause in operations scheduled to maintain machinery and processes for large products like water tanks. It is essential for conducting inspections, cleaning, and part replacements, ensuring optimal equipment performance. For instance, using data from production schedules, an MIS/ERP optimizes maintenance downtime by calculating machine hours and scheduling maintenance when necessary. This proactive approach minimizes unexpected breakdowns, prolongs machinery lifespan, and ensures consistent production levels. Unplanned downtime refers to any unscheduled event that causes a machine or process to be offline, such as equipment failures (e.g., failure of grease), breakages, material shortages, or human errors. It can also be the result of inefficient scheduling, or even slow changeovers between shifts. While planned downtime for maintenance and upgrades is manageable, unplanned downtime is the real culprit, leading to lost revenue and delayed orders.

How to Reduce Downtime:  Best Practices for Downtime Reduction

  • Monitor Real-Time Data: Real-time monitoring systems, offer invaluable insights into machine status, job progress, and resource availability. By leveraging real-time data, operators can swiftly identify and address potential issues in processes like heat induction bending services before they escalate into major downtime events, ensuring proactive intervention and uninterrupted production flow.
  • Properly Train Production Line Employees: Investing in comprehensive training programs equips the manufacturing workforce with the skills needed to identify and resolve issues promptly. Well-trained employees contribute to error reduction, adherence to best practices, and efficient troubleshooting, ultimately minimizing downtime and maximizing productivity.
  • Upgrade Manufacturing Equipment: Outdated machinery is a common culprit behind downtime incidents. By upgrading to modern, more efficient equipment such as the latest mining plant and equipment, the manufacturer can enhance productivity and minimize the risk of breakdowns associated with aging machinery, ensuring smooth and uninterrupted operations.
  • Maintain Effective Changeovers: Optimizing changeover processes is essential for minimizing downtime during product transitions. Streamlining changeover procedures and implementing efficient protocols can significantly reduce the time required to switch between products, maximizing uptime and production efficiency.
  • Continuous Improvement: Regularly reviewing and improving scheduling processes based on downtime analysis is crucial for ongoing efficiency gains. Leveraging advanced MIS/ERP systems enables continuous improvement by providing actionable insights into operational performance, facilitating data-driven decision-making, and driving ongoing optimization efforts via asset resilience.
  • Invest in Technology: Harnessing the power of a robust MIS/ERP/MES system, that can assist in optimizing production processes and minimizing downtime. These sophisticated solutions offer Industry 4.0 features that will monitor, analyse, and optimize workflows empowering manufacturing companies to maximize uptime and manage planned downtime effectively.

 Final Thoughts

The journey towards minimizing downtime and maximizing efficiency in packaging operations requires a multifaceted approach, with digital transformation serving as a pivotal solution. By seamlessly integrating Management Information Systems (MIS) into business ecosystem, the manufacturer is not just digitizing operations – the fundamental way of doing business is transformed. The benefits are manifold: real-time data sharing empowers decision-makers to take immediate action, robust downtime tracking and analysis pave the way for preventative measures, and investments in advanced technologies ensure streamlined workflows and heightened productivity.

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Lean is the Future of Manufacturing

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Lean, a system that reduces production and response times from suppliers to customers, is continuing to transform the manufacturing industry through its focus on efficiency, productivity, and the reduction of waste for producers and suppliers of goods. Amazon, Toyota, and other major corporations are strong proponents of applying the principles of lean to their business. To satisfy a customer base that wants it “now,” Amazon took all their processes apart and found myriad ways to eliminate waste, which for lean manufacturing can mean everything from reevaluating the materials required for producing and shipping a product, to the processes used to get that product from design to customer. Reducing wait times and eliminating extraneous handling and labour through lean improves the bottom line. The capital saved can then be reinvested in new and better products and processes to further improve the customer experience, which in turn fuels business growth.

Out With the Old

The lean manufacturing journey begins by recognizing that the old way of running operations may be holding the company back, and potentially making one less competitive in the marketplace. A heavy steel fabrication company needs to be willing to invest the time and capital needed, or it will result in a failed effort. Once the budget has been set, spend some time identifying areas of waste. This can include wait times, unnecessary processing, overproduction, human movement, excess inventory, and task complexity. Next, set expectations within the company that innovative change such as work sampling is coming, and how everyone will benefit from the forthcoming improvements.

Build a New Pyramid

The first step is to reevaluate the current work pyramid. In traditional manufacturing and structural steel fabrication organizations, the base of the pyramid typically consists of line workers, while the company’s CEO and executive team sit at the top. The new, “lean” way of thinking flips that pyramid, so now, the most important people—those who will be responsible for the company’s continuous improvement—are the line workers. Acceptance of cultural change is important, else manufacturing processes such as heat induction bending services will not be successful. One will end up wasting a lot of money on some shiny new tools that ultimately will not deliver what was being expected. But if one can get over that hurdle, the rest is smooth sailing by comparison.

Hire a Good Coach

To identify the cultural changes the manufacturing organization is going to need to make, it is essential to hire a qualified coach. Comparable to a fitness trainer, a good coach stays for six months or more to teach everything required to know to get into lean shape. They will evaluate the current organizational structure, identify areas of inefficiency, teach teams ways to recognize the importance of communication, coach them through the business transformation, and get everybody working on a continuous improvement path.

Prepare for the Journey

Be ready for the long haul. Once the inefficiencies are identified, develop new repeatable processes designed to eliminate that waste. This includes creating revised roles and responsibilities and ensuring everybody knows their place in the new organizational structure. From there, move on to value stream mapping, where every step of a given process is diagrammed including updating standard work roles and responsibilities for everyone within the company. And do not forget to incorporate suppliers into the new processes. Their symbiotic cooperation will help to strengthen the existing relationship and further propel manufacturing operations. And lastly, strive for continuous improvement, because doing so will uncover never-ending opportunities to improve the company.

Closing Thoughts

Lean manufacturing is a paradigm shift. During that transformation, manufacturers and steel fabrication Australia will find that some employees are set in their ways and will question the need for change. However, once the new organizational mechanics are in place, expect employee morale to improve significantly, because everyone at all layers in the company will feel like valued contributors, which leads to improved productivity. However, it is important to understand that lean manufacturing is not something that happens overnight. Remember, this is a journey, not a sprint!

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Ladd Partners and Cloudteam Company Join Forces as Gold Sponsor at the Rooted-In Manufacturing Conference

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In a significant move that underscores their commitment to innovation and collaboration within the manufacturing sector, Ladd Partners (a consulting services firm for inventory management on Salesforce) and Cloudteam Company (a leading provider of Cloud CRM and ERP solutions across EMEA) will announce their joint Gold Sponsorship at the upcoming Rooted-In Manufacturing Conference, taking place in New Orleans from March 25-27. This strategic partnership highlights their shared vision for delivering technology solutions to help customers drive manufacturing excellence and efficiency using Rootstock and the Salesforce Platform.

“The joint Gold Sponsorship with Ladd Partners and Cloudteam will be a notable highlight at our Rooted-In Manufacturing Conference,” said Matt Wolf, SVP of Global Alliances at Rootstock Software. “Ladd Partners’ unparalleled expertise in inventory management on the Salesforce Platform combined with Cloudteam’s innovative approach to leveraging Rootstock ERP to overcome steel fabrication challenges represent a cutting-edge combination. In addition, with Ladd Partners responding to customer needs in North America and Cloudteam in EMEA, it’s the type of global synergy we strive for in our partner ecosystem.” “Partnering with Cloudteam at the Rooted-In Manufacturing Conference is our first step in enabling our ability to deliver inventory management solutions globally,” said Krista Ladd, Co-founder, and Managing Partner of Ladd Partners. “We take great pride in our ability to effectively deliver salesforce solutions that truly transform our customers’ operations. This partnership allows us to showcase those strengths, and when combined with Cloudteam, we help manufacturers leverage the tools and strategies they need to drive quality management and to achieve new levels of efficiency and growth across both United States and EMEA.”

“Our alliance with Ladd Partners embodies our shared commitment to innovation,” said Gert-Jan Ter Weeme, CEO of Cloudteam Company. “Today, the manufacturing industry faces complex challenges, particularly in demand, supply, and order fulfilment. At Cloudteam, we take our manufacturing clients on a digital transformation journey, helping them to leverage a holistic CRM and ERP solution on the Salesforce Platform. Our Rooted-In sponsorship is a significant step forward in our mission to deliver Salesforce solutions to customers globally, expanding our reach and enhancing our service offerings to meet the dynamic needs of the manufacturing sector.”

The 2024 Rooted-In Manufacturing Conference will include:

  • Ladd Partners and Cloudteam Company customer success stories that demonstrate how manufacturers have benefited from the combined power of their technological expertise.
  • An exhibit area where attendees can meet the companies to better understand their consulting services.
  • Keynote presentations on Manufacturing Mega Trends, Signal Chain Vision, and Accelerating Value with the Power of Salesforce.
  • A Business Track featuring manufacturing leaders driving success in various areas, such as financial management, team empowerment, and reimagined business processes.

A Technology Track to discuss top manufacturing technology trends such as AI, enabling data-driven decisions, integration, and managing data governance.

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Failure of Grease (and the Oil in it)

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Greasing is an age-old practice of lubricating machinery (usually made from metal) with oil. The oil is a thickener which acts much like a sponge. The purpose of greasing is to ensure that metal parts do not rust and that they operate smoothly in different weather conditions. However, greasing is not a foolproof method of lubrication and it may fail in certain cases. This is mostly due to the build-up of contaminants in grease which will hinder proper functioning of machinery. This will also lead to degraded quality of products, increased operational costs and a greater rate of depreciation of plant and machinery. So, how does grease and the oil fail? Let us explore further in this blog.

Oil Oxidation

Oil degradation caused by oxidation, which results in a permanent change to the oil molecules, will mean more frequent re-lubrication is required to replace both the degraded grease and any contaminants which the oxidation has created. The main cause of oxidation is elevated temperatures.  Generally, the rate of oil oxidation doubles for every 150C above 700C.  Therefore, the life of the oil (and hence the grease) is halved for every 150C rise above 700C. Degraded oils break down into by-products of the reaction that are harmful to bearings in steel fabrication. These include carboxylic acids which will corrode surfaces if left in the system and sludge and varnish will form over time. Higher temperatures also increase the rate of oil evaporation and bleeding from the thickener, which reduces the lubrication properties of the grease.

Additive Loss And Other Reasons

Metal fabrication has application in multiple industries, including oil and gas where lubricants are used. Additives that enhance the lubrication properties of the oil such as friction modifiers, corrosion inhibitors, anti-wear agents, oxidation inhibitors, EP improvers and adhesion improvers have a finite life and become depleted in use.  Once this occurs the grease and the oil in it can no longer perform to its original specification. Other factors which reduce the grease and oil life and therefore the re-lubrication interval is: –

  • Dust.
  • Materials and by-products created by wear and lubricant degradation.
  • Humidity and condensation (daily or operational temperature cycles will cause the air trapped in the housing to become a condensate) – an example is mining and plant equipment which is exposed to a humid environment.
  • Water and process-related liquids – The limit for the absolute water content in mineral oil – the lubrication component of most greases – above which problems will occur, is 200 ppm.
  • Vibration – high vibration will cause the grease to churn which will cause a grease life reduction. Vibration will also cause the grease to bleed more than normally, resulting in an increase in the hardness of the grease, limiting its ability to correctly lubricate rolling contact bearings.
  • Strong air flow or reduced air flow through the bearing (drying of grease, oxidation, removal of microscopic oil droplets).

The above factors will each cause a grease life reduction factor of between 0.4-0.7 times the normal grease life in a single row spherical roller bearing.  The reductions are cumulative for each cause and are in addition to the effect of temperature on the grease.

Final Thoughts

There are ways and means to protect against the reduction of grease and oil life. Continuous lubrication is the best preventative method to protect against the build-up of contaminated or degraded grease.  If contaminants have built up in the housing, then to fully remove them the housing must be opened and the bearings and housing thoroughly cleaned.  An alternative is to purge the housing however whilst that may remove most of the contaminants it is unlikely to fully remove them all.  If the contaminants are not removed then the bearing life will be decreased – hence it is essential that the road to operational efficiency is “well-greased”!

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Business Process Integration in Metal Fabrication

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The metal fabrication industry manages intricate production processes and diverse material requirements, and it services customers with high expectations of suppliers. Manufacturers grapple with unique challenges but they can also seize the potential for remarkable improvements through enhanced integration of business processes. The sector is ever more challenging with rising energy, mining plant and equipment costs, workforce shortages and ongoing logistics challenges from almost three years of pandemic disruptions. However, with the right approach and investment, these challenges are not insurmountable. Integrating business processes to elevate the visibility of management information would empower more informed decisions — which are crucial for businesses to thrive. Let us dive deeper into this topic in this blog.

Optimization using ERP and Automation

To confront these challenges head-on, fabricated metals manufacturers should consider implementing a modern enterprise resource planning (ERP) system tailored to their industry’s needs. Generic ERP solutions often need more industry-specific features and functions to support nuanced requirements. ERP systems designed exclusively for manufacturers can streamline processes across the post-pandemic fabrication supply chain. This includes order management, production planning, inventory control, and quality assurance. Such an integrated solution seamlessly coordinates operations and offers real-time visibility into processes, leading to enhanced collaboration, data-driven decision-making, more efficient scheduling, and better shop floor control.

There is an unmistakable shift towards automation in modern metals manufacturing, particularly in operations. This reflects a broader industry trend to optimise efficiency and resource allocation using techniques such as AI video surveillance on the shop floor. As automation takes over repetitive processes, human resources are freed up to focus on managing the more intricate aspects of manufacturing operations. This strategic realignment of human capital enables companies to tap into the full potential of workforces.

MOM – The Operations Bulwark

A pivotal component of this approach is integrating sophisticated systems such as manufacturing operations management (MOM) within an ERP solution. MOM is a cornerstone in providing invaluable support throughout the manufacturing lifecycle, ensuring that precision and consistency are upheld in the most complex manufacturing environments. With MOM’s integration with ERP and its capacity to collect data from the shop floor, manufacturers can achieve consistency and precision that goes beyond what human-centric processes can offer. This integration minimises the margin for error and safeguards the quality and reliability of the product, thereby bolstering overall operational excellence.

Integrating MOM With ERP

Some operational benefits of an ERP system with MOM for fabricated metals manufacturers are:

Advanced scheduling – Advanced scheduling leverages algorithms and optimisation techniques to create optimal schedules, considering machine capabilities, material availability, labour capacity and delivery deadlines. It balances workloads, minimises idle time and enhances productivity.

Streamlining processes – Implementing an ERP system fundamentally centralises and streamlines critical processes across the supply chain from managing the customer order through to delivery and servicing, creating a unified and synchronised operational framework. The newfound efficiency reduces operational redundancies and fosters better decision-making through real-time data access.

Administrative efficiency enhancement – With the adoption of ERP, companies can dramatically reduce administrative overheads by automating tasks such as pipe spool fabrication that were once manual and time-consuming. This boosts efficiency and frees up resources for more strategic and value-added activities.

Visibility informs decision-making – One of the most profound benefits of ERP implementation is its granular insight into production data and key performance indicators. Data-driven insight equips management with the tools for strategic decision-making, driving efficiency and profitability to new heights.

Key Takeaways

In a market characterised by rapid change, manufacturers may not have control over external forces but they can leverage technology to optimise their operations. ERP solutions tailored for manufacturers offer metal fabricators the tools needed to integrate their processes seamlessly, improve the visibility of management information and proactively confront challenges. The path to success in the fabricated metals industry is unequivocal: embrace integration, harness the capabilities of ERP systems designed for manufacturers and use data-driven insights that drive efficiency, profitability, and sustainable growth.

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Strategies to Reduce Manufacturing Cycle Times

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While many industries are now operating as they did prior to the COVID-19 pandemic, manufacturers continue to grapple with complex challenges like global supply chain issues, unpredictable product demand spikes, and delivery driver shortages. These challenges have extended lead times, which, in turn, has placed significant pressure on companies to improve manufacturing cycle times. This has resulted in manufacturers finding ways to streamline their processes, automate manual functions, and redesign products so they are easier to produce. So, what are some of the strategies followed by manufacturers to reduce cycle times? Let us dive deeper into this topic through this blog.

Accessing and Centralizing Data

Manufacturing plants have traditionally been structured in a way that facilitates operations but results in information silos and a lack of transparency. Data is frequently stored in multiple sources such as warehouse and inventory management, manufacturing resource planning (MRP), manufacturing execution systems (MES), and edge computing. Data management is one of the top manufacturing technology trends and it provides an end-to-end view that can guide decision-making and optimize a manufacturing operation. Increasingly, manufacturers are creating a data fabric to centralize their data. This virtualized architecture layer and tool set connect data across disparate systems and creates a unified view. It prevents unauthorized access with unique security controls and automatically optimizes data for performance. Additionally, teams can connect systems without being slowed down by the complexity of traditional data programming, which leads to rapid application development.

Maximize Machine Uptime

A significant contributor to manufacturing cycle time spikes is critical machines going offline. Improving machine uptime builds overall equipment effectiveness (OEE), which measures the amount of manufacturing time that is productive. Machine uptime depends on the quality of the maintenance of the equipment. Some manufacturers only fix machines when they break, others schedule regular maintenance, and some focus on proactive defect elimination. The most effective method is predictive maintenance, such as using AI in video surveillance to improve productivity. Connecting machines and IoT devices allow manufacturers to access data and use analytics to identify flagging performance issues and wear and tear before machines fail. It also ensures maintenance technicians focus on the most urgent problems. With predictive maintenance, manufacturers can identify performance declines before they negatively impact cycle times. It also increases the lifespan of machinery, which reduces the cost of equipment replacement. Predictive maintenance reduces breakdowns by an average of 70% and maintenance costs by 25%.

Identify and Eliminate Bottlenecks

Performance slowdowns can be caused by manual processes, poor work floor layout, or a design that could be improved to simplify product assembly. Even something as simple as extended pipe fabrication setup times can increase operational costs and bottleneck time-to-market. The two critical components to consider are process stability and process speed. Stability refers to the standardization of a process – how much variability is evident? If the average cycle time varies significantly, it will be challenging to make process improvements and accurately measure speed, or efficiency enhancements, so high variability must be the first issue addressed.

Once the average cycle time is stable, performance lags caused by bottlenecks or process deviation can be identified. One way to accomplish this is by utilizing process mining tools. Process mining examines how a process occurs in the real world from log data in software systems. For example, running process mining on water tank development process might identify that employees manually enter data that could be automated or captured via an application form or a photo scan. Or it might be observed that a single handoff between employee stations takes unnecessary additional time. This could indicate the need to change the operations floor layout to shave a few seconds off each handoff (which results in significant savings over time).

Concluding Remarks

While manufacturers can develop strategies to improve floor operations, the correct and appropriate implementation of these strategies is the differentiator between visible improvements and sunk costs. Also, a holistic approach is generally necessary to reduce manufacturing cycle time and quality remains king – after all, reduced cycle times do not help if quality is compromised!

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Belmont Timber gets new ELGi Compressed Air Systems

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A new compressed air system featuring two ELGi EG series oil-lubricated screw air compressors has delivered reliability and energy efficiency gains to a building products manufacturer in Sydney. Belmont Timber, a manufacturer of engineered frames and trusses for the building industry, needed to modernise its ageing compressed air equipment, which was causing manufacturing delays and increasing costs. ELGi Equipments, one of the world’s leading air compressor manufacturers and renowned for enhancing the energy efficiency of its air compressors, with partner Pulford Air & Gas, came to their assistance with two ELGi EG series oil-lubricated screw air compressors for Belmont’s factory in Sydney. To fabricate engineered frames and trusses for the building industry at its 20,000 m2 site, Belmont Timber needs a reliable supply of compressed air to power the machinery. The older compressed air equipment was unreliable and needed increasing maintenance, and was causing a noticeable rise in power consumption. Belmont Timber called on Pulford Air & Gas, its long-standing compressed air partner and one of ELGi’s authorised partners, for a new compressed air solution. On the advice of Pulford Air & Gas, Belmont Timber selected two ELGi EG30 oil-lubricated screw air compressors with refrigerated dryer, oil-water separator, downstream filtration, and heat induction bending services to meet their needs.

Gary Walker, Managing Director at Belmont Timber, said, “Compressed air is essential to our productivity and much of our manufacturing process is dependent on a reliable supply of compressed air. Take for example, our nailing guns used in preassembly. If the compressed air pressure is incorrect, the nails will hang out of the timber, requiring additional work to be carried out to ensure that quality management remains in place. “We had started to get some issues with the reliability of the ageing compressed air equipment, and it required more maintenance. In addition, we noticed that our power consumption was going up significantly. “Pulford Air & Gas has been looking after our compressors for a very long time, so we trusted them to present the best solution to meet our requirements. Since installation, the ELGi EG30’s has provided a reliable supply of compressed air. And, while we haven’t run the numbers yet, we expect to see energy savings as a result of the upgrade.”

The ELGi EG series of oil-lubricated screw air compressors deliver best-in-class energy efficiency. ELGi’s high-efficiency airends are equipped with in-house eta-V profile rotors, with the 4/5 lobe combination, designed to run at optimum speeds. This unique design reduces pressure losses, and together with the OSBIC process (Oil Separation by Impact Centrifugal action) 3-stage separation, increases efficiencies. Ramesh Ponnuswami, Executive Director, ELGi OSEA, said, “Pulford Air & Gas worked with Belmont Timber’s requirements to specify the best compressor solution for optimum energy efficiency and reliability. Aside from delivering energy efficiency gains, the robust EG series compressors also presented a reliable solution. “Designed to meet Australian conditions, they are well suited to performing at extreme temperatures, from cold to hot and from dry to extremely humid conditions, ensuring maximum uptime.” The EG series is backed by ELGI’s industry-leading warranty, which includes a 10-year warranty on the airend, and a 5-year warranty on the compressor package, including the motor, cooler, separator tank, pressure vessel, fan motor, and controller.

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Potential Benefits of Augmented Reality in Manufacturing

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It is no secret that Australian manufacturers and fabricators have been facing enormous challenges over the last few years. This includes tackling a widespread skills gap, experiencing difficulties in finding skilled workers despite job vacancies in Australia peaking at a record 480,900 positions in 2022, managing an ageing workforce with projections that around 40% of the workforce will be over 55 by 2050 and the loss of important skills as older workers head towards retirement. To mitigate these challenges, manufacturers must take their digital transformation to the next level and embrace intelligent technology such as augmented reality (AR) to better support frontline workers. How does AR make manufacturers’ lives better? Let us find out further in this blog.

Industry 4.0 and the smart factory

Industry 4.0 has delivered advances such as robotics in the oil and gas industry, artificial intelligence (AI), AR, and virtual reality (VR). With the rise of the smart factory, technologies such as AR will be the driving force behind increased profitability, better quality goods, and faster production. Already, many enterprises are benefitting from AR through quality control, maintenance, and repair, streamlined workflows, and remote onboarding and training, to improve productivity, enhance safety, and tackle the skills gap. There is incredible potential for AR to be deployed to support frontline workers on factory floors, from manufacturing to food and beverage packaging. AR can equip frontline staff with digitized manufacturing processes through ‘smart glasses.’ These glasses can replace error-prone paper lists or manuals and enable smoothly guided assembly. They ensure the user always has all relevant information in view, and both hands free for their current activity. AR-enabled cameras and sensors can also provide a standard quality assurance system that ensures perfect results in each production step.

AR in action

Users showcase how AR streamlines frontline activities in warehouses and on factory floors of heavy steel fabrication companies. Global soft drink giant Coca-Cola Hellenic Bottling Company (HBC) switched to smart glasses and remote assistance from TeamViewer to improve picking quality and pallet packing accuracy in its warehouse. Using smart glasses, Coca-Cola’s employees at any of its 54 locations can contact experts remotely via video call and get help to restore operations with a minimum of downtime. Management visits and training can now also be carried out remotely over video calls, streamlining and extending the transfer of skills. However, the real value of AR is that it can be deployed anywhere, anytime, to solve multiple challenges. Both Toyota and BMW use AR in the field to help their technicians work more efficiently and effectively to get customers back into their vehicles sooner. Using AR, technicians can contact experts directly through their smart glasses. The camera in the smart glasses captures the mechanic’s exact field of view and the image is transmitted to a remote expert through a video call in real time. The expert assesses the situation, offers technical advice, and helps solve problems efficiently and collaboratively.  Parts of the vehicle’s assembly instructions, including pipe fabrication components, can also be displayed directly in the technician’s field of vision on-site, or instructions can be visually clarified using remote support features. While this improves customer service, it also means that technical support engineers can help far more in-field technicians without wasting a large amount of time on the road.

Closing Thoughts

With Industry 4.0 now commonplace, it is time for Australian manufacturers to move forward and invest in solutions such as AR to help deliver exceptional experiences for their frontline staff. AR lets manufacturers better support their staff while simultaneously improving productivity, tackling skills gaps, and minimizing errors. The AR train is starting its journey and manufacturers need to hop on at the earliest!

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