The competitive global marketplace demands that manufacturers be the low-cost producer to survive. Improvements in productivity, driven by the latest in automation and management policies, can provide the leverage managers are looking for. By Nancy Syverson, Managing Editor Productivity is the critical measure that determines plant efficiency.
For maintenance and plant operations, one device that can often represent significant cost is the sensor, particularly in harsh applications such as chemical and petrochemical processing. Often exposed to or immersed in highly corrosive solutions and subjected to extremely high operating temperatures and other severe conditions, pH sensors are the critical front-line probes that gather and deliver key data.
Specialty chemicals manufacturer Rohm and Haas Co. has reinvigorated its Manufacturing Excellence initiative, to better compete in a tough chemical marketplace. Here's how the company did it. By David Rosenthal, P.E., Rohm and Haas Co., Bristol, PA Global competition, maturing markets, over-capacity plants, increasing environmental pressure, and rising raw material prices continue to challenge chemical-industry profitability.
Investments in infrared thermography will return handsomely when used as part of a well-planned maintenance program. Unfortunately, many companies don't get those returns. In fact, thermography all too often becomes a burdensome expense, and the program is eventually abandoned. One reason this happens is because managers fail to understand the basics of the technology and the needs of their staff who use it.
The conveyer moves dry bulk-food blends without mixing or cross-contamination, and can be placed where needed. GloryBee Foods, founded in 1975 as a one-man operation selling honey, is a Eugene, OR-based manufacturer and distributor of organic food products. The family-run business still sells honey and other liquid sweeteners.
Scorecards offer an easy way to track and evaluate maintenance effectiveness. Here's how to put them to work in any industrial environment. By Mike Cowley, Contributor Industrial maintenance is getting beyond the days when it was called to action only when equipment failed. Plant managers know that maintenance plays a key role not only in equipment uptime, but in production and overall plant efficiency.
What do safety, health, productivity and floor-cleaning schedules have in common? All of these aspects of your plant can be improved by making optimal use of modern floor-mat options. And mats available from textile service companies offer customization options and features that surpass those you’re likely to find in a standard industrial catalog.
GKN Aerospace's largest U.S. manufacturing site, based in St. Louis, is a 1.7 million sq.-ft. under roof, 76-acre campus. The facility specializes in designing and machining large frame aerospace structures, components, and assemblies for aircraft and aero engine manufacturers. It was purchased by GKN plc in January 2001 from Boeing, one of GKN Aerospace's largest customers.
New equipment will help you meet production requirements, but getting it means justifying a capital expense. Here's how to make that process a success. By Lloyd Morgan, Contributor In most modern organizations, everyone competes for the same pile of capital allocated for project work.
When compression packing fails, the consequences can be devastating. Packing failure can cause pump damage, pump failure and unscheduled plant shutdowns, not to mention the cleanup effort. Considering the potential cost impact, keeping compression packing functioning properly may well be the most critical factor ensuring that the pump keeps working.
Dust collection from melt and holding furnaces had been an issue for the Alcan, Inc., beverage-can-recycling plant in Berea, KY. But the air inside the facility is now clean after a installing a CECOaire Fabric Dust Collector System in December 2003. The dust collector system was manufacured by CECO Environmental, a Cincinnati, OH-based maker of large-scale dust- and mist-collection systems.
Competition, customer demands and sophisticated tools like RFID are bringing new efficiencies to distribution operations that will benefit manufacturers at all levels. By Tom Singer, Contributor In the past decade, warehousing and distribution operations have had to cope with a variety of emerging business trends and forces.
Technical innovation has created challenges in maintenance that high-tech manufacturers say can be as complex and costly as the manufacturing process itself. The world has come to expect marvels from high-tech manufacturing. Extraordinary advances in computers, instrumentation, digital cameras, medical devices and other areas enter the market daily, more powerful, smaller and less expensive than before.
While plant managers and other decision-makers are often surprised with the many developments in loading-dock doors, the selection process need not be challenging or time consuming. Here are five steps to help guide the door selection process, based on the goals of improved safety, increased productivity, lower maintenance costs and overall satisfaction.
Nucor-Yamato Steel Co. produces hot-rolled wide flange structural steel shapes, standard channel and miscellaneous channel shapes, car building shapes, H-piling and hot rolled steel sheet piling sections. The company has produced structural steel in Blytheville, AR, since its first mill opened in 1988.
An automated filler cuts as much as seven seconds from the time needed to produce one bag of cement. Rinker Materials Corp., West Palm Beach, FL, is one of the largest producers of bagged cement, ready-mix concrete and concrete block in the U.S. In order to increase productivity at its cement terminal in Port Everglades, FL, the company recently made changes that helped its packaging process run smoother and produce bags that were closer to target weight goals, while providing a safer environment for employees.
Is there any truth to the idea of Web-enabled automation? Is it possible to connect production and processing machinery by their PLCs to the Internet? More relevant, is it practical or profitable? The short answers: First, Internet access can provide compelling competitive advantages for linking manufacturers with service technicians, customers, suppliers and subcontractors.
The federal Manufacturing Extension Partnership program – MEP – is probably one of the most effective government programs out there. Designed specifically to help small and medium-sized manufacturers, MEP has worked with more than 184,000 firms in all 50 states and Puerto Rico since the program began in 1988.
When this New Jersey-based injection suffered a critical loss of business, it turned to its state Manufacturing Extension Partnership program for help. Now the company is a competitor on the world market. Culture change can come in many forms. While it’s often driven by the need to improve poor production techniques or simply by new leadership, sometimes it takes place when a company learns the hard way that its business strategy is about to self-destruct.
Whether your company wants to fabricate, modify or repair, investing in a welder and taking a welding course can provide an excellent return on investment. Many businesses have discovered that they can pay for a unit within two days. Additional good news is that you don't have to be a professional welder to achieve good results.