Behind every product that you hold in your hand is a manufacturing process that has transformed an idea into the product in hand. Manufacturing processes transform an idea into a product using materials and labor. The outcome of the manufacturing process is affected by the labor and the technique followed.
How to identify the optimal solution for your business? This blog looks into 10 most effective manufacturing procedures to consider for transforming ideas into products in the most efficient and productive manner.
Table of Contents
Exploring the History of Modern Manufacturing
To understand how the modern manufacturing process evolved, we need to glance through the history of modern manufacturing. Before the industrial revolution, the market was dominated by handmade products. This period ushered in industrial processes that transformed raw materials into finished products in high volumes. The advent of steam engines and other technologies that enabled companies to employ machines in the manufacturing process. Introduction of machines in the manufacturing process, reduced the need for human capital.
Further, the introduction of mass production and assembly line manufacturing allowed companies to create parts that could be used interchangeably and enabled finished products to be easily made by reducing the need for customized parts. Mass production techniques were popularized by Ford during the early 20th century.
Then came computers and precision electronic equipment that allowed companies to pioneer high tech manufacturing methods. Companies that utilized such specialized equipment carried a higher price and required a higher capital investment, and also required specialized labor to operate. The skills needed to operate machines and develop manufacturing processes have drastically evolved over time. Low skill manufacturing methods/jobs have shifted from developed to developing nations.
What are Manufacturing Processes?
What is manufacturing process or what is process manufacturing? The manufacturing process or process manufacturing is a method in which goods are created by combining supplies, raw materials or ingredients, based on a predetermined formula or recipe. Manufacturing processes are mostly employed in industries where goods are produced in bulk. The process of manufacturing is accomplished through human labor, use of machinery and/or other tools that may include biological or chemical processes. Manufacturing can be on a large scale, or it can make parts that are later assembled to build automobiles, airplanes, household appliances, and more.
Through the different stages of manufacturing process, raw materials are modified to deliver finished goods. In most industries, the manufacturing process begins with the acquisition of raw materials – either natural or pre-processed. Once these materials are received, they are cut, shaped, refined, or blended with other materials to create a saleable item.
Modern manufacturing processes combine machinery and automated technology systems to produce finished goods. Automated technology includes computer controlled equipment, robotic process automation, computer-aided design and manufacturing, and process automation. Employing these technologies can streamline manufacturing procedures, minimize errors and inconsistencies, and improve productivity.
Manufacturing is an integral and huge part of the economy. Globalization has incentivized countries to re-evaluate their manufacturing processes, procedures, and policies, for greater profitability. Manufacturing has never been more crucial to the economic stability of nations. The National Association of Manufacturers reports that U.S. manufacturers account for nearly 12% of total gross state output and employ 8.5% of the workforce.
Converting raw materials into something more useful adds value to the material. The added value translates to increased prices of finished goods, which makes manufacturing a very profitable part of the business chain. As with any type of business, efficiency is crucial in the process of manufacturing. Efficient and streamlined manufacturing processes lead to higher productivity levels and cost savings. To achieve this, manufacturers will have to –
- Eliminate redundancies
- Improve quality of material and labor
- Keep equipment and procedures updated
- Set realistic process goals
- Streamline intake, distribution, and supply channels
Manufacturing sectors from chemicals to electronics rely on strategic manufacturing processes that enable them to meet increasingly demanding production requirements. In a time when customers demand same-day product deliveries, production efficiency is paramount in the manufacturing sector.
Commonly Used Manufacturing Processes
Now that we have a fair idea about what is the manufacturing process, let us get into the types of manufacturing processes. The way products are manufactured has changed over time. The various types of manufacturing processes serve the diverse needs of industries and businesses. The type of manufacturing process you use depends on material compatibility, product complexity, intended use, product design, customization requirements, and environmental impact.
6 most common types of manufacturing are –
1- Discrete manufacturing
This is a type of production process that involves the building of distinct and individual items. The end result of a manufacturing process is identifiable units with unique characteristics, unlike continuous manufacturing where identical products are produced in a continuous flow. This method utilizes an assembly or production line. This is a highly diverse process with a variety of setups and frequent changeovers. This is due to factors based on whether the products in production are different or similar in design. When items are vastly different, it will require altering of the setup and a tear-down, meaning production will need more time. Discrete manufacturing is best suited for businesses that use discrete manufacturing to produce products that can be broken down and recycled.
2- Repetitive manufacturing
This type of manufacturing is used for repeating production to commit to a production rate. Repetitive processing comprises dedicated production lines that produce the same or similar items, all around the year. The setup requirements for this type are minimal and require very little changeover. The operation speeds in repetitive manufacturing can be changed as per customer demands or requirements. The distinguishing characteristic of repetitive manufacturing is the use of assembly or production lines. Manufacturing industries that utilize repetitive manufacturing are automotive, electronics, semiconductor, and durable consumer goods.
The assembly line remains fairly constant, with only a few changes required as one product is manufactured over a period of time. Master plans are created on a period of time and quantity basis. Repetitive manufacturing is often used for make-to-stock production or in a high volume, sales order-oriented environment like automotive. Robots and other automated high volume manufacturing equipment are used to increase throughput and decrease manufacturing costs.
3- Job shop manufacturing –
This type of manufacturing makes use of production areas instead of production lines. Job type manufacturing produces small batches of customized products, either make-to-order or make-to-stock. Organizing workstations in a job shop setting allows manufacturers to make one version of the product or even a few dozen in batches. If the customer demand requires the product, the operation can become a discrete manufacturing line with selected labor operations being replaced by automated equipment. This type of manufacturing is best suited for manufacturers of bespoke products or work on a project-to-project basis.
It is important to bear in mind that job shop manufacturing is not only for low-technology products, it can also be used for advanced manufacturing of fighter jets and rockets for the aerospace and defense industry. These products are produced by highly trained professionals who employ advanced manufacturing techniques and place a strong focus on quality control to ensure a high-quality build.
4- Continuous process manufacturing
Continuous process manufacturing is similar to repetitive manufacturing because it runs 24/7 to create the same or similar products repeatedly. This process can also create larger order quantities. The main difference here is that the raw materials used are gasses, liquids, powders, and slurries, instead of solid-state components. The difference between these two methods is in the raw materials used. Traditional industries that widely utilize continuous include – pharmaceutics, chemicals, fertilizers, power stations, paper, oil refining, and furnaces (steel, iron, alloys). Product designs are similar unless the disciplines to create a final product or a production process are diverse.
5- Batch Process Manufacturing
This type of manufacturing is driven by the availability of raw materials or market demands. The batch process differs quite a bit from continuous process manufacture and is more similar to discrete and job shop manufacturing. The number of batches that are created will be enough to serve a customer’s requirements. The manufacturing equipment will be cleaned and rested in between batches. The raw materials used are more similar to continuous process manufacturing, such as liquids, gasses, powders, and slurries.
Depending on consumer demand, one batch could be enough to meet that demand. After a batch is completed, the equipment is prepared for the next batch. Batch processes are continuous by nature.
6- 3D Printing
This is a relatively new type of manufacturing that is also referred to as additive manufacturing. The 3D printing method was first conceived in the 1980s. 3D printing makes use of a digital model to make 3D products layer by layer using materials such as metals and plastics. Although this type of manufacturing process has high start-up costs, it provides considerable savings in other areas. Businesses using 3D printing save substantially on financial capital, raw materials, and various other forms of waste. Buildings, musical instruments, shoes, firearms, and prosthetic limbs are some of the products that can be produced through 3D printing. Although it is still in its infancy, 3D printing promises to be a potential avenue as a manufacturing technique in the future.
Manufacturing processes are sometimes divided into additional categories like molding, casting, and polymer processing. However, these methods are rarely used in modern manufacturing processes.
Types of Manufacturing Techniques
Depending on the method followed for manufacturing the product, the types of manufacturing processes are – machining, joining, casting, forming, molding, assembly, and finishing.
Machining
Machining is a manufacturing process that involves the shaping and removing of material from a workpiece to create a desired shape, size, or finish. This technique is used to produce a wide range of precision parts and components used in various industries. The machining process can be applied to various materials, such as metals, plastics, wood, and composites, which makes it a versatile manufacturing technique.
Joining
This technique is used to connect or assemble two or more items to form a single, unified structure. Several techniques are categorized as joining – welding, soldering, brazing, adhesive bonding, mechanical fastening, and interlocking mechanisms. One or more of these methods is chosen based on factors like the materials that are being joined, the strength required, and the specific application.
Casting
This is a manufacturing technique that involves pouring a liquid metal (molten metal or alloy) into a mould to create a solid object. This method is used to produce components with intricate designs and complex forms that would be challenging or costly to create using other techniques.
Forming
This type of manufacturing technique is used for shaping and transforming raw materials – typically sheet metal or other malleable materials, into shapes or structures using various mechanical or thermal methods. Types of forming techniques include – bending, rolling, stamping, drawing, forging, extrusion, and deep drawing. The forming technique enables manufacturers to manipulate materials into their necessary forms, from simple bends and curves to complex and intricate webbing.
Moulding
This manufacturing technique involves the process of shaping a material, often in a semi-liquid or liquid state, by pouring or pressing it into a mould cavity. The poured material then cools and solidifies, or cures inside the mould, and takes the shape of the mould cavity. This manufacturing technique is used to create a wide range of products with consistent dimensions and shapes. Plastic bottles, toys, and toilet seats are commonly manufactured using the moulding technique. Different moulding techniques include injection, compression, blow, rotational, and casting.
Assembly
This is the process of combining individual components or parts to create a finished product. Assembly involves connecting, fitting, and joining various elements in a systematic way to form a complete and functional unit. The assembly process can be carried out manually by skilled workers or using automated machinery and robots, based on the complexity of the product and the required volume of production.
Finishing
This is the last stage of the production process that involves additional treatments, processes, or coatings that are applied to a product to enhance its appearance, functionality, and overall quality. The goal of the finishing technique is to refine the final product, ensuring that it meets specific design requirements, performance standards, and surface characteristics, before it is ready for sale or use.
Steps in the Manufacturing Process
Developing the Idea
Manufacturing of any product starts as an idea or concept. Development of concept and growth of the product vision are the first steps in the manufacturing process. The product vision defines the product, the target audience, the need for the product, and who the competitors are. Thorough research while developing the concept helps define a good product and refine the characteristics that will go into the actual product.
Perform market research
Although many believe manufacturing only considers the physical aspect of making the product, the manufacturing process still incorporates researching the potential product to explore ways to make it better. This includes understanding what raw materials are used, the equipment needed, the conditions the product must be made under, and how the product will differentiate from competing goods.
Design the product
Once all the research considerations are in place, it is time to design the product. The design of the product must always be done in consideration of what the customer will need and use. The product design must also incorporate any manufacturing limitations discovered during the research stage. Design considerations also include the costs that will go into the product design so you can forecast your product profitability. Even at the design stage, the manufacturing process is deeply rooted in research and development.
Finalize design and prototype
With the design stage completed, it is time to finalize the product. This includes choosing the raw materials and the manufacturing process to be followed. These decisions are implemented by creating an initial prototype. This means drafting a smaller-scale product that mirrors what the final product looks like.
Test the prototype
Once the prototype is complete, it is time for testing it. Prototype testing includes analyzing actual resources that went into making the product, so that you have a better understanding of how much the actual product will cost and the profit margin. The weaknesses and inefficiencies of the product are also revealed while testing the prototype. Testing the prototype is the final step before mass production begins. However, changes can be made in the future, and this is time for significant changes without major implications on the product or manufacturing process.
Manufacturing the product
Once thorough testing and research is done, it is time to manufacture the product. The company acquires the machinery and equipment required to make full-scale progress towards product development. The company also invests in the full amount of labor, storage, insurance, and other costs related to a full manufacturing line. Once the product is manufactured, companies may choose to continually improve their processes rather than going back to the prototype stage. Continuous improvement is done by reviewing often and implementing smaller changes during the actual manufacturing step.
Monitor the process
For continuous improvement, the company must constantly evaluate how the manufacturing process is going to verify if the expectations are met. The monitoring process must also analyze how much the goods cost to make and compare it against the sales prices. The company must also evaluate product demand and scale up or down based on consumer preference.
Manufacturing versus Production
The terms manufacturing and production are often used interchangeably. But, do they mean the same thing? Although both processes produce finished goods, there are subtle differences between the two processes. In manufacturing, a company needs to solicit raw materials from third-party or external vendors to produce finished goods. In production, the company often owns the raw materials and does not source it from third-party vendors.
Production may be considered as a broader set of activities that include manufacturing processes. The production process simply takes inputs and yields output. Manufacturing on the other hand is a specific type of production that takes raw material and transforms it into tangible finished goods. The end product of the manufacturing process is a tangible good, while in production the end result could be a tangible or an intangible good. Since the manufacturing process relies mostly on raw materials, the dependency on heavy machinery and equipment is also greater. Manufacturing processes also rely on set-up time, and labor to establish the process. In the case of production, the requirement of machinery depends on the expected output.
Process Bottlenecks in the Manufacturing Process
Most of the production or assembly lines have their share of bottlenecks. It is not unusual for unexpected elements to slow down manufacturing systems, which slows down manufacturing systems. It is important to analyze process workflows in order to spot bottlenecks and make necessary improvements. Common spots in the assembly line that are prone to bottle necks are listed below –
Throughput
Throughout refers to the number of products that pass through manufacturing processes. Bottlenecks in the assembly line limit the throughput. Manufacturers can identify bottleneck locations by changing the throughput of each machine in the assembly line.
Accumulation of products
Assembly line supervisors should regularly scan for build up of products and materials throughout the day. It is common for products to get stuck when passing from one production phase to the next. The reason for product or material build up could be machine or operator malfunction. In some cases, improved training of operators and more precise standard operating procedures are enough to fix the problem.
Downtime or Idle time
production lines that involve several machines operating at high capacities are bound to experience unexpected breakdowns. Inoperable devices stall the production processes, which causes ripple effects across company lines. No code workflow automation software like Cflow can help O&M managers automate preventive maintenance scheduling to minimize the likelihood of equipment downtime or worker idle time.
Full capacity
Every production unit has a built-in output capacity. Machines at each stage typically work within a fractional percentage of their total power. If by mistake, operators set one device to work faster than the others, the entire system should collapse due to mistimed production processes. Commonly used method to determine the root cause of productivity blocks is the 5 Whys Method. Once the cause is identified, lean management principles are applied to prevent the cause to recur.
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Process Manufacturing Software
Modern manufacturing companies rely on multiple tools and software to trace and schedule manufacturing tasks to ensure that peak efficiency is maintained. Many process industries use manufacturing operations management software to manage end to end production processes, streamline planning and scheduling, improve quality management, and optimize efficiency.
Process manufacturing software is essentially a set of digital tools that enable manufacturers to plan, manage, and execute tasks efficiently and cost effectively. Manufacturing software is designed to automate and streamline repeatable production processes like materials planning, inventory management, and production scheduling. There are several types of software available for manufacturers, each varying in their functionality and application. The focus however, remains minimizing waste and saving time.
By harnessing the power of automation, manufacturers can produce finished goods faster at comparatively low production costs and fewer errors. Automating repetitive tasks in the manufacturing process results in greater profitability and higher productivity, which in turn facilitates faster business growth. Automation can also improve customer satisfaction, as it ensures that finished goods are manufactured quickly without compromising on accuracy or quality.
The two delivery models for manufacturing software are – On-premise and cloud manufacturing software. The former is licensed and loaded into servers owned and operated by the user. Everything needed to operate the company’s IT infrastructure must be provided internally. Cloud manufacturing on the other hand refers to on-demand production management that does not rely on direct active management by the user. Businesses access cloud-based manufacturing software on a pay-as-you-go basis over the Internet. The Global Cloud Market was valued at USD 69799 million in 2022 and is expected to reach USD 194650 million in 2028 growing at a CAGR of 18.65% in the forecast period of 2022-2028.
As per Fortune Business Insights, the Software as a Service (SaaS) market is projected to grow at a CAGR of 18.4% during the forecast period of 2024-2032. As per the report, the SaaS market segmented by industry shows promising growth in the manufacturing sector. No code automation SaaS software simplifies process automation in manufacturing processes. Cloud manufacturing software continues to trend as businesses move more and more into the digital space.
Manufacturing process management software centralizes information on how goods are manufactured to make production processes more efficient and productive. No code process automation software automates repetitive manufacturing operations from production planning, stock availability, inventory tracking, allocation of resources, and delegation of tasks. Manufacturing automation software lowers labor costs, improves efficiency, and increases profits. Automation standardizes production processes and minimizes human error. The use of process automation software is best suited for manufacturers that produce standardized items in bulk, such as construction and healthcare.
Top 5 Manufacturing Trends in 2024
Manufacturing processes are part of every industry, production of industrial goods for aircraft, automobiles, chemicals, consumer electronics, heavy machinery, and oil and steel. The manufacturing sector has made a paradigm shift from machine-based assembly lines to smart factories that use robotics, the Internet of Things (IoT), augmented reality, and other cutting-edge technologies. A 2023 Deloitte survey on the manufacturing industry outlook outlines the following trends for 2024.
Investing in Technology
Leading industrial manufacturers have increased their technology investments in the following areas – robotics and automation, data analytics, and IoT. Manufacturers have increased their digital investment over the past few years and accelerated the adoption of emerging technologies. Continued investments in advanced manufacturing technologies can help develop the required agility.
Implementing talent management strategies
Addressing the tight labor market and workforce churn amidst shifting talent models remains the top priority for most manufacturers in 2023. Despite having a record level of new hires, job openings in the industry are still hovering near all-time highs. Manufacturers are pursuing several approaches to strengthen their talent retention strategy.
Supply chain disruptions
Out of the surveyed executives, 72% believe that the persistent shortage of critical materials and the ongoing supply chain disruptions present the biggest uncertainty for the manufacturing industry. The increased utilization of digital technology coupled with time-tested approaches helps achieve supply assurance.
Smart factory
Manufacturers are adopting a holistic approach to smart factory initiatives to explore new horizons. Companies will continue to progress towards smart factory transformations, as these initiatives drive future competitiveness. One out of five manufacturers are already experimenting with underlying solutions or actively developing a metaverse platform for their products and services.
Sustainability
Increased focus on corporate social responsibility. Several organizations voluntarily comply with a complex network of reporting regulations, disclosure frameworks, and ratings. Manufacturers are gradually progressing towards fast evolving environmental, social, and governance (ESG) commitments.
Conclusion
The manufacturing sector has progressed significantly from manual manufacturing methods to digitally powered automated solutions. The time and effort that goes into producing a product can be significantly reduced by process automation software. Improving the outcome of the manufacturing process requires streamlining of the manufacturing processes by adopting process manufacturing software. Process automation software like Cflow can eliminate the redundancies by automating the repetitive tasks in the process. The visual workflow builder in Cflow can create automated manufacturing processes within minutes. You can explore Cflow by signing up for the free trial.
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