Strategies To Optimise Your Machine Shop

It can be a massive challenge to resume normalcy post pandemic. However, it need not spell continual declined efficiency if the right strategies are in place to optimise your machine shop.

While machine tool life boasts an average over 10 years (with minimal maintenance) and maybe 20 years (with optimum maintenance), it is always essential to perform health checks and explore possibilities for improvement. However, many machine manufacturers recommend a half-yearly maintenance checks for optimisation, instead of waiting for signs to show up such as strange noises, build-up or operation glitches resulting in downtime and wastage. Nonetheless, machine shops can adopt strategies to enhance machining and metalworking processes.

Revisiting The Setup

Sound resources utilisating cannot be stressed enough. From having the right team with the right skills, your shop has to have the right cocktail of processes to ensure smooth operations. Wastage is the bane of all machine shops. Evaluate the elements you can change to alter productivity rate — even if that means removing steps to cut short production time without compromising quality and value.

Invest In Equipment

Majority of machine shops have equipment operating for years. It is a tall order to implement a sudden migration especially when it is multi-faceted processes. A change of equipment will need a new team who are skilled enough to operate them.

Hence, machine shops can instead explore enhancement options. Examples include automation enabling components such as Internet Of Things (IoT), product life management (PLM) softwares to collate data, detect and execute predictive maintenance. Not forgetting parts replacement; the typical root cause of wastage and downtimes.

As mentioned earlier, make an effort to schedule half-yearly equipment health checks by professionals. It would be a huge bonus if the team is aware of an impending downtime by a malfunctioning part.

Nonetheless, replacing them is a sum worth parting with for long-term benefits, especially not every component is easily accessible depending on compatibility and proximity. Additionally, consider adopting Augmented Reality (AR) when it concerns equipment servicing. Receiving assistance remotely (almost immediately) can significantly reduce downtime and restore operations. Again, an investment which may spook businesses due to high costs.

Skilled Labour Is Gold

With the rapid changes in manufacturing and technology all in the name of efficiency and productivity, having skilled labour is vital. The global manufacturing sector is playing catch-up post pandemic given many equipment makers took the “downtime” to develop new products in preparation for a more competitive market. Having the most advanced equipment is ideal, but it has to be paired with experienced professionals who can operate it.

From what to consider while machining complex alloys, to obtaining the right tolerance across different workpieces, keeping your team updated on the latest technologies can be extremely advantageous as they are your ground intelligence to alert you of risks of being a laggard. In case you are thinking of elaborate courses to pack your team to attend, you just need a couple to attend, and spread the word through periodical meetings.

Maintain, Repair and Overhaul (MRO)

A huge subject on its own, MRO is another multi-faceted undertaking which combines processes and activities associated with the machine shop’s upkeep, including its production lines and equipment, utilities, and related operations. There are four aspects of MRO namely:

Infrastructure Maintenance And Repair

As the word implies, infrastructure refers to the basic physical and organizational structures and facilitiesof the machine shop. Not contesting it is a time-consuming process, there are various vendors who can take on the mission. Upkeeping the machine shop has a direct impact on operations as they involve products, raw materials and equipment.

Equipment Maintenance And Repair

Interlinked to investing in equipment as mentioned earlier, the purpose of this is to prevent any unnecessary unplanned downtime time and minimise material waste. This is where predictive maintenance comes in — where substantial volume of work is eliminated. If the machine shop freezes, everything comes to a standstill till it is resolved.

Material Handling and Equipment Upkeep

This aspect involves ensuring the incoming resources and outgoing products run without glitches. Manufacturing cannot cease, so do goods on their way to customers. Finally, the most crucial part; tools and consumables (including raw materials) also known as MRO inventory. They include all work tools and safety equipment.

Faulty drills, damaged wrenches have no place in an effective machine shop. This calls for religious procurement and optimum resources managing.

It is crucial to prioritise regular equipment checks and maintenance to ensure optimal performance and avoid unexpected issues that can lead to downtime and wastage. Instead of waiting for signs of trouble, machine manufacturers often recommend half-yearly maintenance checks as a proactive approach for optimisation.

By adopting such strategies and continuously seeking opportunities for improvement, machine shops can enhance their machining and metalworking processes, maximise efficiency, and stay at the forefront of the industry. With a proactive mindset and a commitment to excellence, the possibilities for achieving optimal performance in machine tool operations are limitless.

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