Category: Industrial Mechanical

Get Accurate Boat Hulls Thickness for Quality Assurance

Fiberglass reinforced plastic (FRP) is utilized in a large quantity for manufacturing components in the boating industry for two types of boats, work boats and recreational craft. Manufacturers of boats and marine surveyors requires to get accurate hull thickness measurements using a precise wall thickness gauge. Before, unless there was a place to put a micrometre, there was no real way to decide thickness but to penetrate a gap in the body. Present day ultrasonic thickness gauges, be that as it may, make it simple to check the thickness of vessel structures.

Ultrasonic thickness estimations are especially valuable with fiberglass tangle/meandering lay-ups. Varieties in layer thickness make it important to intermittently check thickness. In some cases pontoon structures are made of fiberglass skins sandwiched around an internal centre of balsa wood, stopper, or froth. In those cases, the centre material makes it difficult to make add up to body thickness estimations, since it doesn’t transmit ultrasound, yet the external fiberglass layers can be estimated successfully with ultrasonic hardware.

A wall thickness gauge with the High Penetration programming alternative and 45MG with High Penetration programming are compact gauges equipped for making advanced thickness estimations on fiberglass. They are ordinarily utilized with a M2008 transducer (500 kHz) to boost the entrance of ultrasound in thick or weakening fiberglass, giving a thickness estimation scope of around from 0.150 in. to 3 in. (4 mm to 75 mm), contingent upon the sort of fiberglass. In particularly difficult cases, the progressed 38DL PLUS thickness gauge with the high entrance transducer choice and vast waveform show is prescribed. This design empowers administrators to alter setup parameters on location. Transducers, for example, the M1036 (2.25 MHz) or M109 (5 MHz) can gauge down to roughly 0.050 in. (1.25 mm) in fiberglass.

The 38DL PLUS gauge with the HP choice and the 45MG gauge with the HP choice both have pre-customized default setups for the two transducers most generally utilized for fiberglass estimation, the M2008 and M1036. Much of the time, these default setups can be utilized with no further change, only the two-point speed and zero adjustment that is suggested for all ultrasonic thickness estimations.

The fiberglass utilized as a part of vessel development is by and large of high calibre, and not at all like some different fiberglass overlays does it as a rule not create high sufficiency inside reflections that can cause false readings. In any case, if false readings are seen in a specific case, the circumstance can generally be remedied by little changes of the underlying addition and TDG incline as sketched out in the gauge working manuals. The 38DL PLUS thickness gauge waveforms beneath demonstrate a commonplace hang up on inward reflections, and a right perusing of aggregate structure thickness following a basic pick up modification.


Top 5 Techniques to Reduce Manufacturing Costs

Manufacturers are always looking for techniques to reduce their cost. Here are five of them that will help the manufacturers reduce cost irrespective of their sector. The primary step would be to assess their process and do on internal audit. Only when the big picture is at view, methods can be implemented to reduce the costs.

Energy Efficiency

Most of the time without our notice we tend to waste a lot of electricity. Implementing sensors that would stop the machines immediately after usage can reduce quite a lot of cost. Replacing energy guzzling machinery with those consuming less energy can save up to 10% of the cost. Usage of alternative energy sources like solar energy which is the cheapest source of energy can cut down operating cost significantly.

Fixed Cost Reduction

Machinery for a manufacturing industry is very important, but only a few machineries are constantly used. Hence, owning the machinery that is used passively wouldn’t be feasible; renting/leasing such machinery can reduce the fixed cost. Using automation in production process can decrease the labour cost abundantly. Outsourcing advertising, marketing and sales could also help in cost reduction.

Overhead Cost Reduction

Maintaining inventory by not over producing and recycling/selling the wastage or scrap of the raw material can always free up and manage the factory space and reduce wastage. At times, outsourcing supply can reduce the business space, risk, staff, and maintenance of vehicles. Buying raw materials at bulk and sharing it with another manufacturer can reduce the material and inventory space. Intercom and internet calling, conferencing and video calling meetings can help reduce administrative cost.

Reduction in Labour Costs

Usage of technology for the manufacturing process like implementing sensors and automation, robotics can drop down as the number of labours drops as the automation requires less human interference and is more accurate. Using part time workers and free lancers can eliminate the idle time of labourers. Implementing methods to increase efficiency; comfortable positive workplace, eliminating overtime as it reduces efficiency, training employees, getting to know the employees, reskilling of the employees rather than assigning them monotonous task can help the manufacturer make optimum use of the labour force.

Customer related cost reduction

Technology can help the manufacturer cut down the cost in every stage of the manufacturing process and also at marketing. Using technology for marketing, advertising and promoting of goods can reduce cost abundantly. Designing products digitally 3D print of the product would help the manufacturer in better understanding of customer needs and can reduce correction and reproduction.


5 Challenges Facing the Industrial & Manufacturing Sector

  • Changing Compliance Regulations & Traceability
  • Relevance
  • Skills Gap
  • Healthcare
  • Environment Concerns

The industrial and manufacturing sector keep evolving and that evolution doesn’t just happen. It’s almost always a direct result of overcoming the challenges that threaten the very existence of the sector. So, are there any challenges that the sector is dealing with currently?

Well, here are 5 challenges the manufacturing sector is currently trying to overcome.

Changing Compliance Regulations & Traceability

Changing regulations have always haunted manufacturers. But, they’re there for a good reason. Without compliance standards, manufacturers could very well end up cutting corners, which ultimately ends up affecting the end consumer.

So, for the sake of things such as quality control or proper waste management, compliance standards need to exist. However, complying with new standards isn’t an easy task for manufacturers. More often than not, they’re a burden and thanks to globalization, manufacturers are also forced to deal with regulations that are unique to each territory.

Manufacturers are also tasked with tracking compliance as well. This means that have to go through the entire supply chain to check for compliance, right from vendors to the end-product that’s sent to the customer.

Relevance

As technology evolves, the rate of innovation increases. But, this also means companies have to rush and that can lead to all kinds of temptations. The urge to skip a step or avoid certain tests can be hard to resist when the goal is to market the product as soon as possible.

But, the last thing a manufacturer needs is to put the business at risk with a low-quality product. So, innovation management becomes a must in these situations. Preferences change by the day and any delay in delivering appropriate solutions can mean the end of everything.

So, manufacturers have to establish a system that allows for the consistent delivery of new ideas and innovation. Only this can sustain manufacturing success.

Skills Gap

As one generation exits the workforce, it makes way for a new generation of workers. This transition is, in itself, quite a challenge. But, things are very different today.

Manufacturers face the challenge of filling up those positions with equally skilled members from the current generation. However, the new generation of employees is simply not skilled enough, making the challenge even harder to overcome. As a result, manufacturers have to develop strategies such as working with the education sector to offer the skills training necessary to fill these positions.

Some manufacturers are also retaining skill by extending the retirement age.

Healthcare

As healthcare costs go up, it becomes very difficult for manufacturers to manage their budgets. For instance, in the US, it’s manufacturers who foot healthcare bills for their employees. But, with costs going up, it is simply not feasible and there are no viable alternatives.

Environmental Concerns

Regulations with regard to sustainable and environmentally safe processes and practices put more strain on the manufacturing process. Whether it’s waste disposal or the regulation of materials, more resources are needed to follow best practices.

As you can see, it’s not exactly easy for the industrial and manufacturing sector. However, manufacturers have to figure out a way to leverage technology and innovative ideas to keep up with the changes that pose a threat to them.


Automation of Industrial Processes

The rapid expansion of a huge international market requires the industrial sector to optimize production processes to achieve a greater market share and increase competitiveness. To achieve this, engineering has promoted the development of areas such as mechanics, electronics and robotics to manage and consolidate the automation of industrial processes.

Automation is the implementation of intelligent systems and technologies to operate machinery and control production processes, regardless of human operation in jobs that require greater effort and represent a huge risk to the health and welfare of workers. Currently, there are three types of automation in accordance with the degree of production and needs of a certain industry:

Fixed Automation:

Designed for large-scale manufacturing: A specialized machine or equipment is used to produce a part of a product or the product itself, in a fixed and continuous sequence. This type of automation is ideal for producing large volumes of products that have a long-life cycle, an invariable design and a broad consumer demand. Its main limitations are the high initial cost and the lack of flexibility of the equipment to adapt.

Programmable Automation:

Suitable for a smaller production volume, segmented by batches, programmable automation allows to change or reprogram the sequence of operation, by means of a software, to include the variations of the product. Among the most used equipment for this type of automation are numerical control machines, robots and programmable logic controllers.

Flexible Automation:

Designed for an average production level, flexible automation is the extension of programmable automation. It reduces the programming time of the equipment and allows to alternate the elaboration of two products (in series) when mixing different variables. Flexibility refers to the ability of teams to accept changes in the design and configuration of the product, thus reducing costs for companies.

Advantages of Industrial Automation

  • Decreases manufacturing costs
  • Increases the efficiency of the production process.
  • Speeds the response to market demands.
  • Replaces the man with complicated industrial processes that endanger his physical integrity
  • Favors business competitiveness.
  • Improves the security of the processes and the quality of the production.

Disadvantages of Industrial Automation

  • Generates technological dependence
  • Requires a large initial investment
  • Lack of trained personnel to manage the equipment
  • Susceptibility to technological obsolescence
  • The resistance of the workers to the change

One of the main challenges of the implementation of automated systems in industries is to balance the work done by computerized equipment and robots with the work performed by the operators. While technology helps to optimize processes and limits human intervention, it does not replace it completely. The error is to associate industrial automation with unemployment since human presence is necessary for the management, supervision and control of complex production processes.


Simple Steps To Improve Manufacturing Productivity

Staying competitive in a global economy demands consistent efforts to improve manufacturing productivity. In order to succeed with the objective of sustainable growth and the capacity to generate useful output, manufacturers have to make critical decisions regarding the deployment of resources, implementation of new technologies, elimination of operational inefficiencies, etc. A sound manufacturing strategy plays an integral role in shaping the competitive position of a company.

The more effective your manufacturing productivity, the more profit your company can make. In some cases, it is easy to identify variables that interfere with operational efficiency and productivity. However, it is not always simple to understand the complexity of a process. Once you are determined to improve manufacturing productivity, you will be able to better understand underlying problems and resolve them. Following are simple steps and strategies that can help you improve the productivity of your production plant:

Collect data regularly

As you put efforts to comprehend your manufacturing processes in depth, you become better positioned to enhance your production process. First and the most important thing is to understand manufacturing patterns through data. The number of production hours, efficiency of production machines, time to manufacture each item, output per hour, and productivity of employees are some of the variables that highlight the overall efficiency of a manufacturing plant. Successful manufacturers keep track of everything happening on their factory floors.

Identify bottlenecks

It is very important to locate points in your workflow where production gets backed up because production processes are not properly integrated. Integration of production processes plays a vital role in bringing about an efficient factory floor where everything is connected and works in harmony. So, identify and eliminate bottlenecks in order to develop a more streamlined and organized workflow.

Upgrade manufacturing systems

Old-fashioned, manual production processes cannot meet the growing market expectations. Customers demand high-quality products. It will be extremely difficult for a manufacturer to address emerging market trends without implementing innovation and bringing in modern automation technologies. As a manufacturer, you should continuously look for modern production means that are fast, efficient, and flexible. It is the only way to maintain manufacturing productivity over a long period of time.

Industrial automation solution providers offer a variety of affordable manufacturing systems that you can integrate into your existing setup and witness dramatic improvements. Consult a reputable automation engineering company that can develop custom machines and control systems for your factory floor.


Useful Tips To Maintain A Transformer

Since the transformer is a very important and essential device for an industry, therefore, they have to maintain it properly to ensure its smooth and hassle-free working. If you want your device to work at its full-efficiency, you need to maintain it with the time and here are some useful tips for the greenhorn. So, what are you waiting for? Here are the different parts of the transformer that needs maintenance time to time for delivering the unexpected results. Let’s get started.

  • Oil: Transformer oil plays a vital role in the smooth working of the device and in an order to ensure the fitness of the device; you need to replace the oil with the new one. You need to check them at very short intervals and if any contamination is present, so it should get replaced.
  • Bushings: Examination of the bushing for the cracks is compulsory to avoid any serious damage. This test should be done under the expert surveillance to prevent any risky situation. You need to repair if any crack found on the bushings to keep the device secure.
  • External Or Internal Connections: All connections of the transformer should be tight and unbreakable to prevent a deadly situation from arising. Make sure you invest some money and hire a professional to prevent a big loss in the future. Proper connection is not only important for the safety, but also for the smooth working of the device, so, you shouldn’t take it for granted.
  • Gaskets: Gaskets in the transformer get shrink during the servicing of the device, therefore, it is more than just compulsory to check its tightness or rigidity in their joints. You have to tighten them if any fault found to prevent the situation of leakage that can be perilous for the plant, personnel or property.
  • Temperature Indicator: At the time of maintenance of the transformer, you need to check the instrument that gives you the indication of the change in the temperature level. The proper indication is important and so is its instrument, thus, you need to keep it secure and clean timely to ensure its proper working.

These are a few useful tips that make it easier for you to maintain your transformer to prevent any failure or breakdown of the device. Playing with such heavy-duty appliance is not a good deal, so, you should hire a professional that makes the work easier for you and give you assurance about its smooth and safe performance.


Automation Technologies And Manufacturing Safety

As a business leader, you have to continually search out ways to increase operational efficiency and throughput, and lower manufacturing costs. Besides improving the productivity and streamlining production processes, the working environment is something that demands special attention from business leaders. It is crucial to ensure safe working conditions and reduce incident rates. This can be a challenge to maintain a balance especially when production and safety are in a constant battle with each other.

Fortunately, industrial automation and safety systems have made major advancements in the past decade. Sophisticated automated machines and control systems have bridged the gap between production and safety. Your job is to make sure that your engineering staff is implementing new technologies correctly.

It is a necessity to have a corporate safety plan focusing on the implementation of plant safety technologies. We need to dig a little deeper in order to understand how an integrated production system can contribute to a company’s overall success. Safety management is supposed to provide a safe workplace for employees, whereas, engineering department is tasked with improving the manufacturing process. We cannot separate these disciplines as they are interconnected.

Most of the traditional machine guarding systems are simple in design and do not require an engineering background to implement or understand them. However, traditional machine safeguarding techniques are limited in scope. Modern automation and engineering safety controls are intelligent enough to automatically change the safeguarding methods depending on current hazards.

What if the safety system at your production facility were intelligent enough to allow safe human interaction for tasks that are repetitive, routine, and integral? An intelligent safety mechanism can help you improve the productivity of workers and lower the injury risks. It can have a big impact on your bottom line. The advanced industrial technology offers capabilities necessary to develop an integrated manufacturing process where manufacturers can maintain a balance between safety and production.

The advanced integrated technologies are more complicated than traditional safeguarding devices. The use of safety-rated devices can unknowingly create an unsafe environment where safety is nothing but an illusion. Even the advanced safeguarding solutions come with the risk of creating a dangerous work environment. Therefore, it is important to have skilled engineers who can implement and maintain modern machine safeguarding systems.

If you are not satisfied with the current safety conditions at your production plant, consult an engineering company that can design a better safety plan for your manufacturing unit.

As a leading automation engineering solutions provider, BP Automation offers comprehensive analyze, design, and manufacturing services to ensure you have a one-stop solution for most of your manufacturing problems. We design custom automated machines along with safety solutions for your specific working environment. Reach us to consult and discuss your project with us!


Using Water-Less Technologies in the Dyeing Process

Scarcity of water and water pollution can derail your production process or the supply chain, lead to fights with other water users or damage corporate reputations.
Problems of large water consumption are closely related to the textile industry which has become a global industry in today’s times. Textiles adorn every single item of your daily life right from high fashion apparels and furnishings to the filters in your washing machines and vacuum cleaners. However, the same textiles leave maximum water footprints on Mother Earth and pose a big problem to the delicate ecological balance. Polyester and cotton, two largest mass marketed textiles require large amounts of water in their dyeing process.

Dye houses in the country not only consume huge quantities of water for the purpose and but also discharge large amounts of harmful effluents into rivers or the local streams. Using water friendly technologies or having efficient water management systems in place is one of the biggest challenges faced by the textile industry. It is essential for the industry to undertake major steps to mitigate the environmental harm that is being caused by the dyeing process which uses various dyes such as acid dyes manufacturers, reactive dyes manufacturers, vat dyes manufacturers, basic dyes etc.

Some steps in this regard have been undertaken by several manufacturers. One way is to reduce the dye-to-water ratio, however, the answer to this lies in the mechanisation of the factory’s manufacturing processes. Moreover, the natural fibres pose much of a problem for adopting waterless dyeing methods. Polyester can be coloured in airless environment where dyes are dispersed throughout the material under pressurized high heat. Wool and cotton however, undergo damage if they are passed through this environment.

In-spite of this, several companies have undertaken efforts in reducing water consumption to a great extent in dyeing natural fibres. One effort taken in this regard was changing the molecular structure of cotton such that it permitted the dispersion of dyes throughout the fabric using very less amounts of water. Energy as well as water consumption are said to have been drastically reduced with this technology. Another technique used is to embed textile dyes within the fabric, all the while using air for the dye dispersion process.

Yet another method that has found acceptance in the industry is use of pressurized and compressed carbon dioxide to disperse dye within the fabric. The carbon dioxide which is held in chambers of stainless steel assumes liquid-like properties. After the dyeing process is complete the carbon dioxide takes on its gaseous form and separates from the dye within the fibres. The dye within the fibres condenses and the carbon dioxide is recycled and used again for the dyeing process. However, this is simply said than done as the investment required for the technology is still huge.

Nevertheless, many large companies are aggressively finding ways and means to reduce or eliminate water consumption in their dyeing process and the day when all manufacturers use water-less or near-water-less technologies for dyeing will not be far off.


How to Maintain Industrial Power Equipment

Maintenance of various power equipment is a key part of facility management. The entire operation depends on the power systems such as backup generators, control panels, industrial chargers, UPS, etc. The failure of these key assets can put a production plant in jeopardy. This is why maintenance is of paramount significance so far as the facility management is concerned.

Managing critical equipment demands an auditable process to reduce operational risks. It also has an impact on safety, cost, compliance, and operational throughput. With the growing focus on environmental responsibility and sustainability, it is required to implement risk mitigation strategies.

Businesses have to devise cost-effective strategies in order to survive in a competitive environment and become low-cost producers. Possible situations or risks that can pose a threat to business operations must be anticipated and addresses in a timely manner. It is advisable to prioritize the existing assets for inspection and maintenance. The data obtained from reviews and inspection programs can be used to meet risk mitigation objectives.

What are the techniques to maintain critical power equipment in a facility? We understand the significance of emergency generators in a production process. Backup generators can keep a production process running for years. However, they require regular maintenance. Load bank testing is one of the techniques to maintain a generator.

Load testing a standby generator system must be an inseparable part of the standard planned maintenance program. The process ensures that your standby generators keep producing the designed output.

Battery maintenance is also a critical component of running an efficient and reliable facility. However, the procedure to maintain industrial batteries is slightly technical. Carrying out maintenance activities in the right order can save time and extend the lifespan of batteries and chargers. Besides, make sure you clean batteries in the designated areas using proper tools.

It is recommended to hire a professional preventive maintenance service which can take care of your equipment critical to production and operational activities. An expert in this field will help you establish the appropriate procedures for generator and battery maintenance without affecting the safe working environment. Having a preventive maintenance program in place is a good way to keep your power equipment in good working condition.

Conclusively speaking, regular maintenance activities such as load bank testing, commissioning, inspection, etc. can extend the useful life of your generators and other systems. Reach a reputable contractor that can take good care of your generators and other equipment.


The Future of Manufacturing

From catching a ride to getting instant medical attention, smartphones have completely changed the way people live and carry out their daily tasks. In a similar way, the rapid evolution of operating technology and production means have transformed manufacturing. Innovative companies like Tesla is the best example of how technology can materialize the seemingly impossible ideas and change our view of reality. Modern food processing equipment, robotics, sensor technology, and smart machines are no less striking.

There is something that drives manufacturers to constantly explore means for improving efficiency and agility. Managing market volatility is one of the biggest challenges manufacturers face today. In order to successfully handle this challenge, manufacturing leaders need a sound combination of speed, agility, and responsiveness. The characteristic of being agile and responsive can also help companies deal with a number of challenges, for example, fluctuating raw material costs.

Most of the successful companies focus on improving production processes and enhancing customer relationships. Small companies even pay more attention to meet customization demands and improve productivity. No matter the size of a company, the manufacturer struggles to maximize capacity utilization and achieve annual cost reductions. Implementing innovative production solutions carefully is the only way to achieve these objectives.

Industrial automation technology indicates that there is never any shortage of opportunities to grow and remain profitable. A business manager has to identify strategic opportunities and technologies that can offer the greatest profit potential. It is also important that a new solution should be in compliance with a company’s competitive differentiators and core capabilities.

It is highly likely that by the year 2020, business owners in every industry will have invested millions of dollars in a broad range of automation and fabrication technologies. Nano-manufacturing, 3D printing, artificial intelligence, smart machines, and the Internet of Things (IoT) will dominate the future.

Investment decisions can depend on a company’s priorities and objectives, market conditions and forecasts. Introducing new technologies is subject to a thorough cost-benefit analysis. The way of conducting cost-benefit analysis can vary from industry to industry.

Automation technologies such as robotic welding, smart sensors, quality control systems, metal fabrication, magnetic inspection, and material handling equipment can help companies achieve the following objectives:

  • High productivity
  • Improved data availability
  • Faster responsiveness to customer expectations
  • Production flexibility
  • Improved employee engagement

Small companies must learn how to implement automation and improve productivity in a cost-effective manner. The success in manufacturing now largely depends on how efficiently a company can adapt and meet market expectations.