An assembly line conjures up images of massive conveyors rapidly churning out endless product units, but most assembly lines start much smaller than that, and growing manufacturers should know the pros and cons before choosing to adopt this production method. Here's a broad look at what assembly lines do well and where they struggle.
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Assembly lines were one of the earliest enablers of mass production and remain one of the best methods to scale up production in many industries. An assembly line allows a manufacturer to accept more orders and increase output beyond what was possible before. This is why transitioning to an assembly line (from something like a handcrafted or “cottage” process) is a key sign of growth for a company.
The efficiency and speed of assembly lines also lead to significant cost advantages that come with efficiencies of scale, as the Corporate Finance Institute explains. More units can be produced at a lower cost per unit. Manufacturers can use this advantage in their pricing strategies to widen their profit margins and ultimately bring in more revenue.
Another purpose of the assembly line is to ensure product uniformity. Processes are set up to guarantee that every unit looks, feels, and functions the same way, from appliances to corn chips. Additional QA steps watch for flaws so that the process can be improved over time. This leads to fewer dysfunctional units, less waste, and more consumer trust in the reliability of the product.
Assembly lines benefit from consistent upgrades to improve efficiency and from new technologies or processes. From automation to new raw materials, an assembly line is capable of upgrades to improve production in a variety of ways. This is why many of today’s highly automated and speedy factory assembly lines look much different from the earlier versions begun decades ago.
While assembly lines have many efficiencies when it comes to production, you have to get them set up and running first, which is an expensive investment for a growing business. An assembly line requires factory space, significant investment in labor, and large equipment that may include conveyor belts, furnaces and separators. Installing an assembly line poses a challenge for businesses that want to avoid further debt and introduces many new assets that must be properly managed.
When goods are handcrafted or made one at a time, the quality of an individual unit is largely up to the creator. However, the uniformity of an assembly line requires that all units be produced the same way with the same precise measurements and raw materials – all at high speed.
This often means that when switching to assembly line production, a company must change the raw materials, the product design, and how the product is assembled. That can lead to significant compromises in product quality, and in some cases, may ruin the value that the original product provided. We can see many modern examples of this effect on Kickstarter or Indiegogo, where promising products receive high amounts of investment but ultimately fail because they cannot be effectively mass-produced.
Assembly lines that still require human labor can be a tough sell for an employer. Assembly line work is monotonous, dangerous and dirty, and it requires significant compensation to draw employees. Even then, turnover can be a problem for certain industries.
As Inc. discusses, there is a wide variety of assembly line methods, from cell manufacturing to team production. Even the shape of the assembly line (U-shapes work better for some production methods, less so for others) and how delivery times are managed can vary depending on a company’s strategic decisions. It takes research and experience to find the right assembly line methods for a particular manufacturer, plus a willingness to optimize as time goes on.
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Today’s industrial robots work in a wide range of industries, from semiconductors and automobiles to plastics processing and metal forging. Pretty much any repetitive operation is a great job for a robot, particularly if it’s dangerous or difficult for people.
The application of robots in manufacturing industries is particularly valuable. Robots have been used for high-volume operations, but as the technology advances and the cost of industrial robots decline, more options and opportunities are opening for medium- and small-sized operations.
At the same time, these robots are helping manufacturers address many of the key challenges they face, including tight labor pools, global market competitiveness and safety.
If you’re curious whether robots can enhance your value stream, here are the main pros and cons to consider:
Along with other tech — such as the industrial internet of things (IIoT) or 3D printing robots — industrial robots are able to provide better production quality and more precise and reliable processes. Added benefits also include reduced cycle times and real-time monitoring to improve preventive maintenance practices.
An industrial robot increases speed for manufacturing processes, in part by operating 24/7. Robots don’t need breaks or shift changes. The speed and dependability of robots ultimately reduces cycle time and maximizes throughput.
Using robots for repetitive tasks means fewer risks of injury for workers, especially when manufacturing has to take place under hostile conditions. In addition, supervisors can oversee the process online or from a remote location.
The cost of having a person handle many manufacturing operations is often more expensive than robot. This can also free up workers so their skills and expertise can be used in other business areas, such as engineering, programming and maintenance.
Some argue that robots are taking jobs away from U.S. workers, but that's not necessarily the case. Industrial robots there are typically integrated into a series of operations that require human expertise. For example, you could have a robot welding parts that are handed off to a person to perform a task that requires a human's intuitive "if, then" thinking.
Robots typically require a large upfront investment. As you research your business case for purchasing, consider all the costs of industrial robots, including installation and configuration. You should also evaluate whether your robot can be easily modified if you need to alter operation in the future.
Industrial robots need sophisticated operation, maintenance and programming. While the number of people with these skills are growing, it's currently limited. As a result, it's important to consider the personnel investment you'll need to make to bring in that expertise or “retool” your existing staff to take on the task.
While industrial robots may reduce some manufacturing labor costs, they do come with their own ongoing expenses, such as maintenance. In addition, you’ll want to consider the costs to keep your robot and any related IIoT connected devices protected from cyberthreats.
Interested in learning more about the types of industrial robots that would benefit your manufacturing business? If you’re ready to explore options, contact Wipfli to request a complimentary consultation.
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