Introduction:
For high-mix, low-volume (HMLV) manufacturers, the push to automate may seem challenging. Your shop handles a variety of parts and often deals with smaller batch sizes, requiring frequent setups and diverse tooling. But today’s automation solutions are increasingly designed to meet these specific needs, offering flexible, efficient options that improve productivity while maintaining the adaptability HMLV shops need.
In this post, we’ll explore key strategies to successfully automate a high-mix, low-volume environment, with insights from automation expert John Lucier. These steps will help you reduce labor strain, optimize machine utilization, and achieve greater consistency—without sacrificing flexibility.
For more on this topic, check out John Lucier’s Seminar on Automation for High-Mix, Low-Volume Shops.
Why Automation Fits High-Mix, Low-Volume Manufacturing
In HMLV manufacturing, automation can serve as a powerful solution for repetitive tasks, process reliability, and consistency across diverse parts. Automation helps improve spindle utilization, reduce reliance on skilled labor, and extend operational hours, ultimately allowing shops to produce more with less effort and fewer resources.
“Automation in high-mix, low-volume isn’t just about making things faster; it’s about freeing up skilled labor and creating consistent output across multiple parts,” says John Lucier. “When it’s done right, automation enhances flexibility rather than restricting it.”
Steps to Implementing Automation in an HMLV Shop
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Identify the Repetitive Tasks
Start by pinpointing the repetitive tasks in your production process. These are often the ideal candidates for automation. Part loading, unloading, inspection, and packaging are common processes that can benefit from automated handling, freeing up operators for more complex, skilled tasks. -
Invest in Quick-Change Tooling and Flexible Workholding
Automation in a high-mix setting relies on minimizing downtime during changeovers. Quick-change tooling and adaptable workholding can make setups faster, allowing you to switch between jobs without compromising spindle time. This way, your automation setup remains active and productive, even as job requirements shift. -
Consider Collaborative Robots for Adaptable Automation
Collaborative robots, or cobots, are well-suited for HMLV environments. They work safely alongside human operators and can easily be reprogrammed for new tasks. Cobots can assist with part loading and unloading, inspection, or simple assembly tasks. These robots offer the flexibility your shop needs without requiring major space adjustments or complex programming.“Cobots are ideal for high-mix shops,” Lucier notes. “They’re adaptable, safe, and capable of performing repetitive tasks, which allows operators to focus on higher-value work.”
Explore Morris Automation Solutions, including cobots, here.
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Implement Smart Monitoring and Scheduling Software
Automation goes hand-in-hand with smart software solutions that monitor job flow, equipment health, and productivity metrics. Using automation software to schedule jobs, monitor tool life, and even provide predictive maintenance alerts can enhance efficiency, making high-mix production runs smoother and reducing costly downtime. -
Design for Unattended Shifts to Maximize Productivity
Even in HMLV environments, automation is able to deliver significant unattended run time of your machine tools. While automation has always been able to excel in high volume applications, the flexibility of automation these days allow for quick change over between low volume jobs. This allows users to easily capture time lost throughout the day, whether that be over lunch breaks, shift changes, or short overnight runs. The next job is easily brought online, and the automation takes it from there. -
Collaborate with Automation Experts for a Tailored Solution
Because HMLV automation setups can be complex, it’s beneficial to work with a trusted partner experienced in tailoring automation to unique operational needs. At Morris, our Productivity Specialists offer customized support and strategic advice to help your shop design an automation setup that maximizes productivity without sacrificing flexibility.Connect with a Morris Productivity Specialist to discuss automation for your HMLV shop.
Benefits of Automation in High-Mix, Low-Volume Manufacturing
- Reduced Setup Time: Quick-change tooling and collaborative robots minimize the time spent during job changes, allowing your automation to remain productive.
- Enhanced Consistency: Automated processes provide uniform quality across different parts, even with varying batch sizes.
- Maximized Skilled Labor: By automating repetitive tasks, your skilled operators can focus on complex projects, increasing efficiency and job satisfaction.
- Extended Production Hours: Lights-out and unattended shifts allow you to produce more without additional labor costs, even if it’s just during breaks or overnight.
“Automation isn’t about replacing people—it’s about making processes more efficient,” says Lucier. “For HMLV shops, automation can help operators focus on more complex tasks, while ensuring repetitive work is done consistently.”
Conclusion: Embrace Automation for a Competitive Edge
With the right approach, high-mix, low-volume shops can benefit significantly from automation. Flexible systems, collaborative robots, and quick-change tooling allow you to adapt to different jobs without losing productivity. By partnering with experienced automation experts, you can design a setup that keeps your shop flexible and efficient, no matter the batch size.
For more information, watch John Lucier’s seminar on automation for HMLV shops here.
Explore Morris Automation Solutions and see how we can help you achieve smarter, more flexible manufacturing.