Why blended machines meet Six Sigma and Kaizen standards better than batching machines
Thursday, September 03, 2020
Optimizing a business to be efficient is a never-ending race. There are two concepts that business organizations rely on when working on optimization — the Six Sigma and Kaizen.
Six Sigma was invented by the legendary Bill Smith while working for Motorola and is focused on 99.99966% of produced product features without any defects. It focuses on accuracy and precision in manufacturing by identifying potential causes of defects and removing them.
Kaizen is a broad concept of improvement and development of every person in a company, from floor workers to CEOs, with the goal of continuous growth. Kaizen is the Sino-Japanese word for improvement.
We’re here to discuss how blended machines fit these concepts better than the classic batching machines used in fluid manufacturing, packaging, and storage.
Reduce needed equipment and storage containers
Blended machines conserve floor space as they don’t require large storage tanks. The transfer of liquid is much faster. Due to this, it opens up a lot of space to optimize the manufacturing process, conserve time, and human resources.
Blended machines streamline the process while taking up a fraction of the floor space. They also allow a quicker fluid species change and are more flexible when it comes to producing smaller volumes of liquid products.
Storage also becomes an integrated part of the manufacturing floor instead of a separate process that just seems to share the same workspace as the rest of the manufacturing system. Automated electronic control of the machines allows for less foot traffic on the factory floor, ensuring less chaos and confusion.
Consolidate factory space
When we talk about efficiency, we don’t only mean that the manufacturing process is smooth and without defects. It also implies efficiency in the space used to organize your manufacturing floor.
Switching from batching to blended machines allows you to clean up the factory floor a bit, maybe introduce new product lines and ensure that your space isn’t as cramped as before. This means that your employees will be able to move around more freely, reduce the possibility of errors due to hectic work conditions, and easier supervision.
First of all, blended machines allow superior electronic control and automation than their batch counterparts. Due to this, the process of production is easily quantifiable and can be tested to great accuracy.
Blended machines are also known to produce less waste and disposable material. The waste of product components is also reduced. Furthermore, fast species change and smaller volume production opens up new possibilities for scheduling and increased production. No matter how committed you are to manufacturing one product, you’ll switch between products on the fly if the situation requires, which would be impossible without blended machines.
Even when cleanup is necessary, the process is much more comfortable and takes far less time. The packaging of the liquid product is also automated and takes less time.
Finally, the product manufacturing quality and consistency is far more stable than with large scale batching systems. Less loss, more time, more flexibility — what more could you ask for?
As you can see, Six Sigma and Kaizen philosophies go hand in hand with the decision to switch to blended machines. The sheer efficiency of manufacturing due to this simple switch allows companies to keep in line with these two business philosophies.
Suppose you are searching for a way to move your fluid manufacturing organization to the next level. In that case, blended machines should be a serious consideration, especially if you aim to meet the strict requirements of Six Sigma and Kaizen.
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