Manufacturers today are grappling with significant pressures—ranging from workforce shortages to heightened customer demand for greater product variation and customization. For small and medium enterprises (SMEs), high-mix manufacturing, where a broad array of distinct products is produced in varying volumes, brings unique challenges. However, the rise of automation offers a pathway to not only mitigate these challenges but also unlock new opportunities.

The Challenge of High-Mix Manufacturing

In the surface finishing industry, over 93% of companies employ less than 100 employees, according to the National Association for Surface Finishing. Other manufacturing sectors share a similar proportion of smaller operations. For these companies, managing the complexities of high-mix, low-volume (HMLV) production can be resource-intensive, involving frequent equipment reconfigurations and increased labor demands.

However, labor shortages across manufacturing persist. According to a study by Deloitte, manufacturing compensation costs rose by 6.2% in Q1 2022 to attract limited skilled labor supply, with the total cost per hour worked reaching $42. These shortages are especially problematic for industries like general metal fabrication, furniture, and construction, where HMLV manufacturing is common. The high turnover and training costs associated with such operations also contribute to reduced efficiency and profitability. 

Why Automation is a Game-Changer

Automation technologies, particularly those tailored for SMEs, offer a promising solution to these workforce and operational challenges. For instance, collaborative robots (cobots), advanced sensors and AI-based solutions are becoming more accessible and cost-effective, allowing manufacturers to streamline complex production processes.

Key Statistics on Automation Impact:

• Studies have shown that as much as 87% of processes in manufacturing production, including sanding, polishing, graining, and buffing, are automatable​.
• Automation can help reduce operational costs by 15-30%, depending on the level of process complexity​.
• Rework costs can account for up to 10-30% of production expenses in some industries, but smart manufacturing technologies can reduce rework and scrap costs by 20-50%.
• 95% of manufacturers using automation reported improved product quality due to consistent performance and fewer human errors​

The Smart Finishing™ Robotic Workcell: Tailored for High-Mix Production

Our Smart Finishing™ Robotic Workcell is designed to address these challenges and offers a solution for SMEs dealing with high-mix operations. Unlike traditional machines, which require extensive configuration, programming and setup, our system adapts to different product specifications and finishes parts with minimal downtime between production runs.

This helps mitigate workforce shortages while ensuring high-quality output across a wide range of materials, shapes and types of parts. By integrating our product, companies can better manage fluctuations in demand, reduce reliance on manual labor, and streamline production processes.

Conclusion

For SMEs navigating the complex world of high-mix manufacturing, automation presents not only an opportunity for increased efficiency but also a pathway to future-proofing operations. By leveraging advanced technologies like the Smart Finishing™ Robotic Workcell, manufacturers can boost productivity, reduce costs, and remain competitive in an ever-evolving industry.

Now is the time to explore the automation solutions that will help you meet customer demand, optimize processes, and reduce costs in an increasingly competitive landscape.

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