Increasing Manufacturing Productivity

Manufacturing companies looking to increase their productivity at work can start by pinpointing areas of their workflow that are lacking. When they discuss the processes in their business, they have to keep in mind several factors such as employees, the hardware used by them and the physical act of production. They may also consider other variables including the level of communication across the workspace and the different resources required to complete the task.

Make sure that equipment is working properly

It can cost a lot to replace manufacturing equipment, which is the reason why manufacturers should consider maintenance as their top concern, especially in terms of manufacturing productivity. Loans for business equipment can help a lot in covering such expenses however, it is important to keep machines working at full capacity and to have employees that are competent in operating these machines. If they do not know how to troubleshoot for bugs or recalibrate the equipment, it will be more difficult to improve productivity in manufacturing.

Continue to train employees

It is useless for a manufacturing company to have the latest trends in technology if their employees have not been trained to operate them. Considering that technology changes at a very fast rate, they need to invest in their workers’ continuous education and training, which is critical for manufacturing productivity. This technique can be added to their strategy to overcome labor shortages in manufacturing.

Remove unused machinery

Maintaining even a small number of machinery that are not being used can reduce manufacturing productivity. Aside from creating clutter, it lets the company spend more on maintaining equipment that does not make any profit, which should be avoided. They should get rid of useless parts, tools and machines as well as think about equipment leasing or equipment loans so that obsolete machinery will not be left hanging around later on.

Optimize the floor plan

Obviously, optimizing the floor plan is one of the best way to improve the manufacturing process. They can look into the layout of their floor plan to guarantee ultimate workshop efficiency. When they organize tools, equipment and materials the proper way, they will improve marketing productivity as well as keep the workplace safe for employees to work.

Be smart when it comes to stocking up on inventory

While manufacturers should have a steady resupply of inventory to meet the demands of production but there should be a healthy balance. Maintaining too much stock can cost a lot to store and hurt their net profits. They should implement right pricing to help maintain that balance.

Encourage communication
As the saying goes, teamwork makes the dream work. Companies should make sure to give open avenues for employees to communicate their viewpoint since this will help to improve manufacturing productivity, especially when there are issues that they may not be aware of. Having strong communication will strengthen their efforts to unite the team in terms of the business’ core goals.

Filtering Cloth Manufacturers Can Help Your Business

If you do not have a filter press in your office, filter cloth manufacturers may be able to provide you with new and refurbished options. Most filtration companies dedicate themselves to the development of high quality, cost-effective equipment that gives you the confidence of a smart buy. There are several types of presses available, and a company should work with you to determine what your press needs are and how best to meet them. There are several considerations to consider such as size, space, and production output. A quality company helps you address those considerations in the most efficient and cost-effective manner possible.

Manufacturers should also provide filters for your equipment. Presses require a fabric material to help separate the liquids from the solids in the process. Most presses operate on the same basic principle. Operators feed slurry (a combination of liquids and solids) into the machine, and a moving plate clamps several filter plates together. Those plates are typically made of fabric, and the liquid in the slurry passes through the cloth and out through the pipes, leaving the solids behind.

In addition to standard cloth sizes that fit most presses, filter cloth manufacturers can work with your business to create custom fabrics if needed. There are also several types of materials:

– Gasketed and non-gasketed
– Centerfeed and cornerfeed
– Membrane
– Plate and frame

Once you have a press operating within your business, most filter cloth manufacturers also provide additional parts to cover the natural wear and tear of your equipment. These parts might include hydraulic modules, controls and gauges, plate shifter parts, and pipes. Once a manufacturer’s sales representative determines your business needs, he or she can recommend the various products you may need to complement your equipment. It is also valuable to choose a company that offers technicians to help replace those parts.

Besides the equipment, a good manufacturer provides additional services, as well. Customer service is an important part of the buying experience, and many manufacturers make it a top priority. You want to choose one that works with you, provides appropriate product suggestions, and offers additional services. Aside from customer service, additional services should include filter cloth removal and installation, field services for repair, a laboratory, and refurbishing or rebuilding equipment. Companies that go beyond this level of service include helpful instruction and support videos for those businesses that wish to change the plates in-house.

Filter cloth manufacturers should be partners in helping your business grow, and the right one will provide the products and services to do just that. Start with a basic search of companies, and then determine which ones have the experience and service standards to meet your business needs.

Finding a Manufacturer For Your Apparel

If you have a unique garment or apparel product that you need from a manufacturer, here are some tips to get you started.

Search Directories & Lists – There are many directories and manufacturers lists having 1000’s and 10’s of 1000’s of apparel and apparel manufacturers listed there. This is a way to find manufacturers, but it can be very time consuming to sort and contact all of them to start the weeding process.

Many manufacturers will only work in high volume, so even though you can get someone to respond to your request, sometimes this is telling you that in order to serve you, they will need you to order a much higher quantity.

View Apparel Samples – Most clothing manufacturers will include pictures of the types of products they have produced. Maybe they can produce shoes, bags, suits, t-shirts, dresses, children’s clothes and other items. If you need a specific type of clothing, looking for a manufacturer who has proven themselves in that field can save you time and hassle.

Get Some Quotes Before You Commit – Make sure you compare quotes from at least 3 different clothing companies before you decide who you will work with. Make sure each company you consider explains to you their routine for starting work on a new product. What is their price for the first sample? If you search online, make sure you have all of their contact information so you have a few different ways to contact them if you need anything.

Clothing Manufacturer

Clothing is of course produced by skilled individuals; There are many different manufacturers that make a variety of different garments. Depending on the material, the items are produced in different ways, some are sewn by hand, some are machine sewn, and some are made by completely different methods.

Manufacturers of their own clothing brands to distinguish them from others, some are mass produced and sold cheaply to the general public, an example is Primark (a very large company that mass produces their goods and sells them at low prices) they are a family friendly company that offers clothes that fit the whole family.

Other manufacturers are classed as designer – these companies do not produce their goods on the same scale and offer clothing for different types of markets. All of their products are uniquely designed for the latest styles and fashions, they often cost more but can be a testament to why.

Some designers make special cuts called ‘one off’. This is a very unique item of clothing that requires a lot of work and attention. As the name implies, manufactured items are the only pieces that will ever be made and as you might expect, one unique item of clothing can cost a lot of money.

Examples of some companies that are classified as Designers:

energy
Diesel
D&G
star G
Fire trap
and much more…

Why not try searching the internet for clothing manufacturers and see what you can find, there are many different companies with their own style and clothing.

Finding Optimal Air Compressor Oil

While it may seem easy, the universal recommendation for any air compressor is to use oil from your compressor manufacturer. Even so, there are times when you really need to get a new oil change and you’re short on shops or even time to buy oil from your air compressor manufacturer. In this case, you need to know which oil to use for your compressor.

First thing you want to know is that you must utilize non-detergent oil. The reason for this is that air compressor engine does not produce combustible materials and residue as normal engines make. So, every air compressor oil is non-detergent. Nowadays, you have two different types of oils. Regular compressor oil and synthetic compressor oil.

For most of house use, you are completely fine with standard compressor oil since you do not actually need supplied gains of synthetic oils, so having cheaper oil is not so bad as it would be for industrial usage. If you are thinking to use your compressor for heavy-duty purposes, I would recommend synthetic oil.

Air compressors will in whole run satisfying on 30 weight typical air compressor oil but you need to acknowledge that this oil operates optimal on temperatures from 36 to nearly 100 degrees. If you need to use your compressor in lower temperatures, a 20 weight oil is recommended. Common guideline is, the warmer the weather, the more weight you want and the other way around.

Synthetic oil supplies quite a few gains over regular oil. A 30 weight 100% synthetic oil can work below freezing temperatures while also supplying you with much prolonged running time. Operating time of synthetic oils goes from anywhere from two to eight THOUSAND operational hours which in turn implies you do not require to change it very often. Since it’s synthetic, it will offer the maximal protection for your compressor, so if you are not really on a budget, I would recommend getting synthetic oil for all applications. Even so, I do understand that peculiar compressor oils are reasonably expensive and that in most cases you could exchange it with non-detergent synthetic motor oil. Some of the compressor manufacturers are even starting to recommend Mobil ONE synthetic, common motor oil as a substitute.

While synthetic oil offers many gains over regular oil, you should not really worry much about it. I mean, air compressors have run 10-20 years on regular non-detergent motor oil, which is not really made specifically for air compressors. That being told, I still feel a lot better when using oil that is being made specifically for my type of air compressor. This is nonetheless a familiar feeling which manufacturers readily exploit. While it is true that manufacturer oil is optimal, substitutes are viable and will not do any damage to your compressor. It all comes to how much you use your compressor.

Let me set it this way, first option is the oil that is made for your exact compressor. Second is dependent upon how much you use your compressor. If You are not using compressor for industrial or extreme service, it is best to go with common 30 weight non-detergent oil ( modify its weight to suit the climate you are working in).

If it is an air compressor that is used for industrial or heavy-duty, you should really go with synthetic compressor oil. Using other oils is not so effective if that is the case.. You can also apply Mobil 1 Synthetic motor oil if you do not care to search for compressor oil, it will not create much of a difference (if any).

Finally, I would wish to bring up something that should not be common practice but it has its purpose. You can put a straight up normal motor oil, even detergent oil, into your compressor. I mean, there are valid reasons you should not do that, but do not be fearful to apply it if need arises. If you absolutely have to utilize your compressor and you are out of non-detergent oil, you can pour in any regular oil (even hi-detergent one) into it and continue working. People were doing just that for years and years and no serious damage has come out of it.

Just remember if you have to use detergent oil, do not be reluctant to do so but you truly should (not to say must) get non-detergent air compressor oil first chance you have.

Air Compressor Oil

There are various reasons why you need an air compressor. Air compressors can be used on a small scale, such as to inflate bicycle tires, or they can be used for large-scale purposes, such as to deliver power to your engine and repair shop. This large scale use of air compressors may require utilizing the air compressor oils that many people in the industry use for their compressors. Using air compressor oil will not only increase the efficiency of the air compressor used, but will also extend the life of the air compressor you are using.

Purpose of Air Compressor Oil

Many people don’t realize the value that air compressor oil can have on the air compressor itself, but there are many benefits that one can get by using oil in his compressor. First, the main purpose of air compressor oil is for lubrication. When air compressor oil is added to a compressor system, the job of the oil is to use a spark lubrication technique that will lubricate the bearings and engine cylinders. In other words, an oil bath is supplied to the compressor so that it operates more efficiently than a simple air compressor would operate.

What Type of Air Compressor Oil to Use?

Although air compressor oil may be a mystery to many people, the oil used for air compressors is basically no different from ordinary motor oil, although many say there are differences. However, there are several types of air compressor oil that can be purchased. Synthetic oils can be purchased if you want a performance boost, but regular air compressor oils include 20W/ISO68 air compressor pump oils, as well as 30W/ISO100 air compressor oils. These two oils are among the most commonly used for air compressors. However, overall, using air compressor oil in your system is a good idea not only to have a better air compressor, but also to increase the work capacity that your air compressor will do!

You Need to Know When Buying a Reciprocating Air Compressor

Are you thinking about buying a reciprocating air compressor for your workshop, garage or business? There are some things you should know before buying one!

An air compressor is a huge investment, so take your time to learn about air compressors and the different models and options.

Buying the wrong air compressor will not only get you disappointed (in terms of usefulness or power or air output), but can also set you up for huge maintenance bills in the future.

Here are 10 things to think about BEFORE you go to the store to buy a reciprocating air compressor.

1. Compressor type

There are basically 3 types of reciprocating air compressors:

  • Single stage compressors
  • Two stage compressors
  • Twin compressors

Single stage units compress the air in one stroke, from ambient to end pressure. They typically go up to 20 CFM (cubic foot per minute) at a pressure of 125 psi

For more power, you will need a two stage compressor. A two stage compressor uses two stages to compress the air to the end pressure. This means your compressor will have two cylinders/pistons.

The big cylinder is the low pressure stage, while the small cylinder is the high stage. In between the stages the air is cooled.

Two stage air compressors go up to about 50 CFM capacity at about 175 psi.

Whether you need a single or two stage compressor ultimately depends on the amount of capacity (cubic foot per minute) you need.

2. Capacity and pressure

The capacity (CFM) and the pressure of the air compressor are the two most important specifications.

To find out the capacity that you need, simply add up the air consumption of all the air tools that you will use.

Small tools like nailers use only a little air, while big tools like sanders and grinder use lots of compressed air!

To find out the pressure that you need, check again the specifications of the air tools that you plan to use. The highest required pressure dictates the pressure that you need.

It’s always smart to buy a compressor that is capable to deliver more than you need. You will probably add more tools in the future, and almost all compressed air systems will have a leaking hose or coupling somewhere!

3. Horse power

You DON’T need to know the horsepower of the air compressor.

The horsepower is a result of the required pressure and capacity that you need, not the other way around.

Don’t look at horsepower. Look at capacity (CFM) and pressure (psi).

4. Electrical connections

You wouldn’t be the first happy new compressor owner that comes home with an air compressor that he is unable to wire up!

Know the voltage that you have at home. Know the maximum current that your wiring can handle. Do you have single phase or 3 phase power?

Installing extra electrical wiring (or even having 3 phase power installed at your home!) can be more expensive than the air compressor itself!

5. Noise

Do you plan to install the compressor inside or outside?

A reciprocating compressor makes a lot of noise. Always check the noise level of the compressor before buying one. If you are buying a compressor in a shop, ask them to run it, so you can hear what is sounds like.

To reduce the noise, you can make an enclosure around the compressor. Make sure you add enough ventilation holes (and a fan if necessary). An air compressor creates a lot of heat, so adequate cooling is required!

6. Tank size

Most reciprocating compressors come with a 40 – 80 gallon tank, which is fine.

A larger tank size is always better. A bigger tank means that there is a bigger compressed air buffer.

A bigger compressed air buffer is useful when you use big tools that use more air than the capacity of your compressor. Pressure will drop more slowly with a bigger air tank.

7. Compressed air filters

How clean do you need your compressed air?

Compressed air is hot, wet and dirty. Depending on your application, you need to filter it and remove water and oil.

If you use compressed air for paint-spraying, you don’t want oil, water or dust in your compressed air, the air needs to be very clean.

If you only use it for powering air tools, you don’t want water in your compressed air but you don’t really care about oil.

There are filters available to remove water (droplets), oil, and dust. For even dryer compressed air, you need to get a compressed air dryer.

8. Other options and extra’s

There is a list of options you should thing about. Do you really need them, or are they optional?

  • Pressure regulators – to regulate the tank pressure back to a stable, lower pressure
  • Size and number of air connections
  • Vertical or horizontal tank
  • Manual or automatic drains

9. Weight

Most (online) stores will drop your new air compressor on your drive way. You will need to bring it into your garage or wherever you want to place it yourself.

Your new air compressor will probably come on a wooden pallet. You can choose to keep it on the pallet, or remove the pallet.

Think about how you will bring your 600 lbs air compressor to its place before you buy it!

10. Duty cycle

Last, but definitely not least!

The duty cycle is the percentage of time your compressor can run.

Most single stage compressor have a duty cycle of only 50%. This means that when you run your compressor for 5 minutes, it needs 5 minutes to cool down.

Most dual stage compressors have a duty cycle of 100%. They can run 24 hours per day when needed.

If a compressor has a 100% duty cycle, it is often advertised. Beware when the duty cycle is not mentioned.. it is probably only 50%!

Shopping for a Portable Air Compressor

The first thing you should do is write down each tool that will work together. Next, you need to calculate the frequency of compressed air consumption and the volume of compressed air that the appliance will draw from the compressor storage tank. If this all sounds really confusing, don’t stress, it’s all revealed in this article.

Locating the perfect air compressor which will deal with the sort of jobs that you will be undertaking is often quite a tricky process. Having said that, with some standard information with respect to the way air compressors work, the terminology employed in the compressor market along with the difference between the sorts of compressors, it starts to get a whole lot easier to choose the top compressor for ones particular requirements.

Technological terms:

Being Familiar With all of the compressor technical terminology is critical when making your compressor purchase decision. Despite the fact that the quantity of compressor types is often overwhelming, selecting the right unit can be made easy by asking a few essential questions.

Performance Ratings:

Matching an air tool or tools Standard cubic feet per minute and PSI demands to an air compressors output capacity is vital. Standard cubic feet per minute or SCFM is the rate of how much air the compressor can produce in just a minute. All tools which are powered by using a compressor come with a SCFM value; this value will point out the air supply that is compulsory for optimum operation of the tool. Therefore, check the standard cubic feet per minute at 90 psi when matching your air compressor SCFM ratings.

Normal standard cubic feet per minute consumption

Air Filter Cleaner: 3

Air Hammer, light: 4

Air Hammer, heavy: 22

Air Hoist, 1000 lb: 5

Air Motor – 0.5 hp: 6 – 10

Air Motor – 1 hp: 12 – 15

The standard cubic feet per minute consumption of air tools can vary from tool to tool, several tools only have to use 1 or 2 SCFM whilst others will need 10 – 14 standard cubic feet per minute.

If you think there is the possibility that you’ll operate multiple tools at the same time, then it is evident that you’re going to really want way more power. In such a case, determine the lowest SCFM rate for your compressor by adding together the cumulative SCFM specifications for the equipment you will be operating simultaneously. To give a bit of a buffer to the calculations you will need to add an additional fifty percent on to the final number.

Air tool 1 = 2.0 SCFM + Air tool 2 = 1.0 SCFM add these together and the total is 3.0 SCFM, add the 50% buffer and we have a total of 4.5 SCFM (standard Cubic Feet Per Minute), and as a result you would be trying to locate a compressor with an SCFM rating of over 4.5 SCFM.

The smallest SCFM compressor rating can be determined by adding together the SCFM ratings of any compressed air tools which will be used at the same time. In the case when a single air tool is to be operated alone then you must go with the SCFM of the highest rated air tool.

Power:

Electric operated compressors commonly are powered by a typical 110-120V power supply. Although, air compressors that have a motor unit of more than 2 HP may have to have a 220-240V power supply. If you plan to work with your air compressor in a workshop, garage or any other confined place, you need an electric powered compressor.

Petrol operated air compressors do not rely upon electrical energy so therefore they are truly mobile. Though, there are numerous negatives with the gas powered compressors. The most important disadvantage is the fact that the petrol driven air compressors produce harmful gases and as such shouldn’t be run inside or even in any kind of confined work area. One another downside of these compressors is they need much more repairs and maintenance than their electric run counterparts.

Decibel Levels of a typical compressor:

Sound output is an important factor when purchasing an air compressor. Air compressors come with a sound levels listing within the makers specifications and if you are generally operating the device inside the house or in a small workshop you might want to decide upon a quiet machine instead of risking damage to your hearing by using a deafening air compressor. So you should find out the noise level before buying.

Big Challenges in Manufacturing Industries

Regulatory Compliance and traceability: Manufacturers from all sectors face increased regulations aimed at ensuring product safety to manage disposal and reclamation procedures. Consumers can benefit from multiple regulations, and each regulation adds an additional burden to companies that must comply with the requirements. Complete visibility in global supply chains is ensured by manufacturers and they can attest to their own respect as well as from suppliers. Regulations require the ability to track where certain items have been used or to trace materials from the final item at the customer’s location back to the specific materials used in manufacture. Observing regulations and managing compliance reporting is a full-time activity for many people or teams in many manufacturing companies.

To Keep Products Relevant: Product innovations come at different speeds and manufacturers struggle to keep up. With the company’s new concept competing to be first in the market, the temptation to skip a step on quality materials can be a challenge. There should be sufficient time for the company to ensure that certain materials such as cables and wires are suitable for operating conditions. A new product needs to develop a reputation for good quality to drive away bad quality. Companies will become more systematic in managing innovation than leaving new product ideas to chance. Preferences in products are changing so rapidly that they delay the introduction of once popular products. For manufacturing success, it is important to implement procedures to keep a steady flow of new product ideas and innovations.

Aging Workforce/Skills Gap: Age-appropriate, workers retire and leave their workforce and take their hard-learned skills and experience with them. Retired workers are not readily available for replacement because the new ones do not have the skills required for many important roles. Producers should work with schools in their communities to check whether the education system includes topics and skills training for young workers to fill these roles. In addition, manufacturers may need to be more flexible with an aging workforce so as to allow workers to slow down by working part-time rather than retiring suddenly. This will enable aging workers to pass on their skills to the next generation of workers.

Environmental concerns: Various aspects of the manufacturing process are affected by local and regional regulations, from the ability to use certain materials, worker exposures, to the disposal of waste and by-products. There is a harsh environment for manufacturing and therefore must ensure the safety and health of workers with proper care and equipment. Disposing of waste products and recycled materials adds to the cost and complexity of manufacturing and also results in a healthier environment and protection for workers and customers.

To maintain a balance with output: In a manufacturing unit, it is very important to keep the equipment functioning. Preventive maintenance should be carried out on a regular basis including worn wires and cables which helps increase output and ensures customer satisfaction with delivery lead times. Manufacturers are sometimes tempted to delay preventive maintenance or replace factory components with lower-quality goods. This practice creates unsafe conditions in harsh manufacturing environments if these smaller components do not withstand operating conditions. Operating costs can be kept low and output high by using components, cables and wires that meet or exceed manufacturer’s specifications and perform preventive maintenance according to the recommended schedule thereby ensuring worker safety. By meeting these challenges, manufacturing companies can stay abreast of current laws and technology and be responsive to meeting the needs of workers and act responsibly in the best interests of all parties.

Plastic Injection Molding Works

Use of plastic injection mold

Plastic injection molding is the most common and widely used method for mass manufacturing of plastic products worldwide due to its convenience and ease of use. Plastic products made by this method include plastic chairs and tables, covers for electronic products and disposable spoons and knives, as well as other tableware products, for commercial consumption.

History of Injection Molding

Injection molding was originally created to solve a problem that many pool players face. The 19th century billiard balls were originally made of ivory, obtained from ivory taken from elephants. Celluloid was one of the first plastics used to manufacture billiard balls.

Procedure Explained

The scientific procedure used for the manufacture of plastic products by injection molding application is quite simple. Your plastic is melted and taken into a giant syringe. It is then put into a forming mold of a suitable shape according to the product being made and cooled for a sufficient period of time until it reaches the desired shape. However, the actual practical process of injection molding is not that simple and can be broadly divided into 3 subdivisions – injection units, mold parts and finally clamps.

The plastic pellet is gradually poured into the injection unit through the tunnel which is gradually melted and is in a fully liquid state by the time it reaches the front of the barrel. After reaching the forming mould, it is cooled to solidify into the desired fixed shape. The mold then returns to its previous original position in the machine.

All injection molded objects start with plastic pellets, which are a few millimeters in diameter. They can be mixed with a limited amount of pigment, called “dye” or with up to 15% recycled material – then the mixture is fed into an injection molding machine. Early molding units use a pusher to press from above. However, the exterior is either too hot or too cold and the smelting process is not going well. The solution to this is reciprocating threads – often considered the most important contribution no less than a revolution in the plastic product manufacturing industry.

The screw induces the shear stress required to melt the plastic – with residual heat coming from the traditional heating band surrounding the machine. When molten plastic is injected into the mold, it releases air from vents placed on the sides. The plastic, which has the consistency of honey, is thick enough not to slip through these holes, which are only a few microns wide.

Engraving witness marks on plastic products is also an important part of marketing because you need to be able to see and find multiple witness marks and dividing lines to authenticate and verify the authenticity of the product. It is made using removable inserts and proves very useful for tracking defects.