MAY - JUNE, 2022LOGISTICSTRANSPORTATIONREVIEW.COM 19MORE AND BETTER, WITH LESS: HOW TO AUTOMATE FOR IMPROVED QUALITY, UPTIME, AND PROFITABILITYBy John Connell, Vice President of SLI Products Group, Crown Battery ManufacturingThe wrong batteries can cost a fortune in downtime and delays, and even put your business at risk. Likewise with the wrong automation projects. Yet automation is at the core of reliable batteries--and profitable manufacturing. Combined with the right employees and training, it can solve your critical business problems and ratchet up your profitability--all while improving quality, uptime, per-hour labor productivity & output, workplace safety and ergonomics, and customer retention.I'm betting you already know that. But do you know where to start automating, and which projects are dead-ends? In this article, you'll discover some of the hard-won best practices we've learned from investing decades and millions in automation, including: Five questions to ask before you start any automation Common automation mistakes to avoid Proven strategies to prioritize projects (with real-world examples)Should you automate it?Here are five questions to ask before you automate a process: Can it be automated? Is automation technically possible? How much would automation cost? Be sure to factor in costs for R&D, equipment, software, ongoing maintenance, training, and updates. How much does this work currently cost? Include labor, insurance, and other costs. Remember: The goal isn't eliminating jobs; it's optimizing productivity to build better products in less time (we're actually adding jobs as automation helps us grow). What benefits (quality, safety, etc.) can automation deliver? Profits aren't the only goal; for instance, machine safety automation improves worker safety. Is this project the best use of resources? Sometimes, you can achieve the same goals­more and better, with less--in other ways (for instance, by enhancing working procedures).Where should you start?Some automation projects have an outsized impact on your clients, your operational safety and quality, and your bottom line. For us, it was welding. Many battery companies still weld using a traditional strap process from a bygone era: workers manually attach lead lugs to a strap, then burn them together by hand, one-by-one, using an open flame. In optimal conditions, the best welders can make just 40 adjustments. And weak points, cold or hot spots, and incomplete burns are possible.We wondered, "Could that process be automated?"It took Crown Battery more than half a decade to develop a new Cast-On-Strap (COS) system (sophisticated machinery that fluxes battery plates and lead lugs together simultaneously at a precise temperature). Candidly, optimizing the process required more money and time than we'd planned--we've since learned to budget for this.INSIGHTSCXO
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