How to increase capacity utilisation and efficiency in your production
Automation in variant manufacturing is no longer a theoretical concept – it is a reality in manufacturing companies. The key question for production managers and decision-makers is: How can production output be increased even with highly varied processes? This article shows how automation and production control systems help to increase utilisation rates, reduce downtime and stabilise production in the long term.
Since the 1980s, production volumes have been falling steadily. At the same time, growing product customisation has led to increased variance. This development presents manufacturing companies with a key challenge: how can I utilise my machines economically with changing parts and small batch sizes?
The reality in many manufacturing companies:
With conventional machines in multi-shift operation, the utilisation rate is often around 60%.
Automation primarily addresses the times when machines could run without operating personnel. The goal is to
- Process parts without manual intervention
- Minimise changeover and downtimes
- To operate machines outside of operator shifts (night/weekends)
This is not just about robots or handling devices, but about holistic process automation that is tailored to the specific range of parts and the existing technology.
A production control system is not part of the machine control or automation system, but a separate component. The SOFLEX production control system organises production processes and networks machines with or without automation equipment for largely autonomous production. It is the ideal link between the ERP/MES/PDM level and production. SOFLEX solutions are used for everything from individual machines and production cells to smart factories, where several production cells need to be coordinated with each other.
Functional advantages of a production control system at a glance
Order management: Planning based on production orders and availability of operating resources.
Automated data provision: NC programmes, tool data, tool presetting and loading are provided automatically.
Operator support: Work instructions, clamping instructions and test specifications are available directly at the workplace – in text and visual form.
Operating data acquisition: Not just data acquisition, but active information in the event of alarms or declining productivity.
Active control: Direct control of machines, automation systems and handling devices.
Measurable results
With production control systems, utilisation rates of over 90% can be achieved. The goal: 24/7 operation with simultaneous flexibility – even with small batch sizes and frequently changing parts.
Organisational downtime is largely eliminated. Technical malfunctions cannot be prevented, but they can be rectified much more quickly thanks to early detection.
Guided processes and standardised procedures ensure quality and make it reproducible. Every production step is documented and every deviation recorded. The result: less waste, higher first-pass quality, traceable processes.
A production control system not only addresses individual processes, but also creates holistic production control that works even for small batch sizes and large numbers of variants.
Conclusion: From 60 to over 90% utilisation rate
Automation in high-mix manufacturing alone is not enough to sustainably reduce production costs and significantly increase machine uptime. The integration of manufacturing execution systems as a higher-level control and information platform is crucial. This is the only way to reduce downtime, make meaningful use of data and systematically optimise processes.
For this effect to be permanent, the production control system must be designed to be manufacturer-neutral. Only a solution that is independent of specific equipment and manufacturers can be used on different machines and automation concepts, offer standardised interfaces such as OPC UA, ensure uniform operating procedures and guarantee consistent data exchange with higher-level organisational systems. This keeps production flexible, scalable and secure for long-term investment.
Automating variant production therefore means addressing both technical and organisational levels. This enables manufacturing companies to create stable, flexible and future-proof production – even with small batch sizes and a high degree of variant diversity.
About SOFLEX
SOFLEX has been developing manufacturer-independent production control systems for automated production facilities since 1984. With over 2,200 installations worldwide, we support companies in the mechanical engineering, aerospace, medical technology and tool and mould making industries.
Our solutions control flexible manufacturing systems – from individual machines and production cells to smart factories.
Author (Franz Klaiber)
Franz Klaiber - expert in production control technology
Franz Klaiber is the founder and managing director of SOFLEX Fertigungssteuerungs-GmbH. For over 40 years, he has been developing and supporting practical solutions for the digitalisation and optimisation of production processes.