With change to improved productivity and process efficiency
For some time now, the topics Industry 4.0, Smart Factories and connectivity in a new dimension have been dominating the image of the media. Automation has arrived in German medium-sized businesses for a while now, but in many cases the implemented solutions offer room for further gains. There is a demand that medium-sized companies strive for a higher degree of automation in order to remain internationally competitive. But is there really a causal connection? Where exactly are the advantages of a higher degree of automation? Why should a functioning process be changed? All these and more questions are asked by operators of complex processes in medium-sized businesses and industry.
When automation is addressed internally by responsible, statements such as "the processes have grown historically and cannot be automated" or "automation costs too much money. It isn`t worth it" come up. A further point, but one that should not be underestimated, is that especially in medium-sized businesses, operational changes to procedures and processes are also managed on a very emotional level.
One great wisdom is: "Never Change A Running System". However, this is not about never optimizing a system because it is basically running. Rather the opposite is the case. The system should not be changed in its function at exactly the moment when critical processes are actively needed. This results in the actual recommendation to define optimization windows in order to smoothly integrate automation solutions and not to disturb running processes.
But what exactly speaks in favor of automating existing processes?
If the decision is ultimately made to optimize and automate internal processes, the first step is an analysis of the current situation. It provides a comprehensive description of existing process. The data obtained is used to determine target/actual deviations and to identify weak points and their causes. Even "historically" grown structures can be mapped and optimized in this way. In addition to the own demands on the in-house processes, the customer requirements, for example on the quality level, are also increasing. Industrial automation makes it possible that simple steps no longer have to be performed manually, which reduces the error rate. Incorrect entry of data, data records being mixed up or misunderstandings between departments are eliminated by the use of automated machines. New automation technologies also provide a paradigm shift in quality assurance and transparency. They enable data to be collected and analyzed in real time. This enables the localization of further optimization potentials, the control of quality features or the documentation of traceability. Process reliability is also affected by this, so that it is increased with a growing number of variants and the flexibility for a product change is given. All this even with small batch sizes. Another point is that automation gives hope for a relaxation of the labour market. The shortage of skilled workers is currently making it very difficult to recruit qualified employees. A recent survey by Hays AG shows that 48 % of managers in the mechanical and plant engineering sector are expecting the shortage of skilled workers to ease. Although automation and digitalisation do not make it possible to replace a highly qualified employee, they do make it possible to relieve them of unproductive routine activities. They also help to produce important forecasts and simulation results that can be used to make projects economically viable.
But how do you proceed if the resources for planning and implementation are not available internally?
Many entrepreneurs resort to external service providers in such situations. They provide advice and present optimization possibilities. However, another company is often needed afterwards to implement the defined measures. In some cases it is even necessary to commission and coordinate several companies. In order to support users in medium-sized businesses and industry optimally with their processes, the company VWH GmbH from the Westerwald has increasingly positioned itself in the direction of process automation. In addition to the core businesses of special machine construction and toolmaking, the service sector for process optimization in production and logistics is being continually expanded. This offers the advantage that customers have "one" contact person available to them from consulting and analysis to the complete implementation of measures. VWH GmbH thus acts as an interface between customers and all necessary components. Due to own special machine and tool construction, implementations in the field of automation are carried out quickly and easily.
How can low cost automation be flexibly designed?
Low cost automation, or lean automation, refers to automation based on existing resources - i.e. the existing structures and equipment of companies. In order to optimally adapt automation technology to the user and his initial situation, appropriate experience and knowledge of the industry are necessary.
VWH GmbH works together with the customer to develop the appropriate automation solution for a specific application. The full range of services extends from consulting support for the optimization and automation of production and logistics processes, through the implementation of low-cost automation, to the realization of fully automatically linked systems. Open and transparent communication helps to make the right optimization decisions. Processes can often be optimized with simple tools. Or automation can be increased step by step and in line with requirements through a modular structure.
