In the fast-paced world of sub-contract packing, staying ahead of customer demands is crucial. With the rise of automated production lines, companies can streamline their processes and significantly boost productivity. However, to fully capitalise on these advancements, businesses must address the challenges associated with frequent machine changeovers. This is where the concept of a digital storeroom, such as AddParts, combined with on-demand manufacturing, comes into play.
The Importance of Change Parts in Automated Production Lines
Automated production lines are the backbone of modern sub-contract packing companies. These lines rely on various change parts, also known as format parts, to adapt to different product specifications and packaging requirements. The ability to quickly switch these parts is essential for maintaining efficiency and meeting diverse customer demands.
However, the frequent changeovers required to accommodate different products can lead to increased wear and tear on these parts. This not only results in higher maintenance costs but also poses the risk of production delays if parts break unexpectedly. Understanding the vital role these change parts play is the first step towards enhancing the efficiency and reliability of automated production lines.
The Solution: A Digital Storeroom for Flexibility and Efficiency
To address the challenges of frequent machine changeovers, sub-contract packing companies are beginning to turn towards digital storerooms like AddParts. A digital storeroom is an innovative solution that provides a centralised platform where all change parts are catalogued and tracked. They leverage advanced technologies to manage and store change parts online without the need for large warehousing. This ensures that parts are always available when needed, reducing downtime and enhancing production efficiency.
With the AddParts system, users can check their order history, download certificates of conformity, check pricing of replacement parts, and much more. The digital storeroom offers several key advantages:
- Centralised Inventory Management: By providing a central repository for all change parts, a digital storeroom ensures that parts are easily accessible and well-organised. This reduces the time spent searching for specific parts and improves overall operational efficiency.
- Real-Time Monitoring: With real-time monitoring capabilities, companies can keep track of the condition and availability of their change parts. This proactive approach allows for timely maintenance and replacements, minimising the risk of unexpected breakdowns.
- Automated Replenishment: The digital storeroom can automate the process of replenishing parts. When a part reaches a predefined threshold, the system can automatically place an order for a replacement, ensuring that stock levels are always optimal.
Digital 3D Technologies: A Game Changer for Sub-Contract Packing
While a digital storeroom provides a robust framework for managing change parts, the integration of AddParts’ on-demand manufacturing and digital reverse engineering takes it a step further. On-demand manufacturing, particularly through additive manufacturing (3D printing), allows companies to produce parts as needed, rather than maintaining a large inventory. Reverse engineering through the use of a 3D scanner creates a replica of a part in a very efficient and timely manner.
On-Demand Manufacturing Benefits
- Speed: Additive manufacturing can produce parts within 2-5 days, significantly faster than traditional manufacturing methods. This rapid turnaround is crucial for sub-contract packing companies that need to respond quickly to customer demands. In fact, AddParts’ fastest turnaround to date, from reverse engineering the part on the customer’s site to the customer fitting the replicated change part, is just less than 20 hours (including travel time).
- Customisation: On-demand manufacturing allows for high levels of customisation. Companies can produce parts that are tailored to specific requirements, ensuring a perfect fit and optimal performance. AddParts’ carton throat case study highlights what a difference this can make.
- Cost-Efficiency: By producing parts on demand, companies can reduce inventory costs and minimise waste. This lean approach to manufacturing is both economically and environmentally beneficial.
3D Scanning Benefits
Speed and Convenience: Traditional methods of creating digital models can be time-consuming and labour-intensive. 3D scanning streamlines this process by quickly generating accurate digital representations of physical parts. This efficiency saves time and resources, allowing AddParts to update customers’ digital inventories promptly.- Accurate Replication: When used alongside traditional methods of reverse engineering, 3D scanning captures intricate details and precise measurements of existing parts, ensuring that digital models are exact replicas. This high level of accuracy is crucial for creating reliable digital inventories that can be used for on-demand manufacturing and other applications.
- Modifications and Improvements: The digital models created through 3D scanning give a basis for corrections to design flaws, design enhancements, or further customisation. Any improvements that are made to the design are recorded during AddParts’ data capture activities, which include the 3D scanning.
Combining Digital Storerooms and Digital Technologies
The synergies between digital storerooms, 3D data capture, and on-demand manufacturing offers sub-contract packing companies unprecedented flexibility and efficiency. With AddParts’ service, customers can have parts back and on the production line within 48 hours. Here’s how these technologies work together to benefit sub-contract packers:
- Seamless Integration: The digital storeroom can be used alongside on-demand manufacturing systems, allowing for automatic production of parts when stock levels are low. This seamless integration ensures that companies can maintain optimal stock levels without the need for extensive physical inventories.
- Reduced Downtime: With quick access to custom parts, companies can minimise downtime during machine changeovers, ensuring continuous production and high levels of customer satisfaction. This rapid response capability is crucial in a competitive market where meeting customer demands promptly can make a significant difference.
- Enhanced Flexibility: The combined solution provides the flexibility to meet diverse customer demands without the need for extensive inventories. This enables companies to adapt swiftly to market changes, offering a competitive edge. The ability to produce custom parts on demand means that companies can cater to unique customer requirements efficiently.
- Reduce Write-off Costs: When upgrading to new machinery, existing spare parts will be written off as a loss but with digital storage, physical stock can be run down to a minimum in favour of digital stock which will not be written off as a loss and can (in some cases) be turned into an asset.
How Digital Technologies Improve the Packing Industry
The integration of digital storerooms and on-demand manufacturing not only enhances operational efficiency but also drives innovation in sub-contract packing. Here are some specific ways these technologies improve the industry:
- Improved Quality Control: Digital technologies allow for better quality control throughout the manufacturing process. By using 3D scanning to create precise digital models, companies can ensure that every part meets exact specifications. This reduces the likelihood of defects and enhances the overall quality of the final product.
- Streamlined Supply Chain: A digital storeroom simplifies the supply chain by reducing the need for physical warehouses and extensive inventory management. This streamlining leads to cost savings and improved efficiency, allowing companies to focus on core business activities.
- Sustainable Practices: On-demand manufacturing supports sustainable practices by reducing waste and optimising resource use. By producing only what is needed, companies can minimise excess inventory and reduce their environmental footprint. This approach aligns with growing industry trends towards sustainability and responsible manufacturing.
- Enhanced Customer Experience: With the ability to quickly produce custom parts and maintain high-quality standards, sub-contract packing companies can offer a superior customer experience. The flexibility and responsiveness provided by digital technologies ensure that customer needs are met promptly and accurately.
Conclusion
In the competitive landscape of sub-contract packing, leveraging technology to enhance efficiency is not just an option; it’s a necessity. Automated production lines, supported by AddParts’ service which includes a digital storeroom and on-demand manufacturing, offer a powerful solution to the challenges of frequent machine changeovers. By adopting these innovations, sub-contract packing companies can ensure they are always ready to meet customer demands, minimise downtime, and maintain a competitive edge in the market.
Embrace the future of sub-contract packing with digital storerooms and on-demand manufacturing – where efficiency meets flexibility.
* We will supply parts as quickly as possible. Our fastest turnaround lead time is under 48 hours which assumes a single component from digital stock that has been ordered previously and that the part is dispatched by courier. Typical lead times are 5-7 working days for standard components and up to 15 working days for complex, multi-body components with post-production treatments and additional fittings. Please ask for more details on specific components.
