If the goal is to enhance the profitability of the enterprise, then it is necessary to work on improving productivity. Production optimization is aimed at making wise use of its resources. If the enterprise starts to operate more efficiently, producing an increased number of products per unit of time, it will result in significantly lower financial costs per unit of product. The available funds will also be directed towards beneficial purposes — increasing staff salaries, their development, purchasing or upgrading equipment, and more.
Optimization allows for maintaining competitiveness. Cheap, yet equally or more quality products attract customers from direct competitors, which further increases the profitability of the business. Economic efficiency often increases through work on material and technical factors, which include the implementation of modern production technologies, automation, and the use of new materials.
Analysis of the current state of the production line
The audit of aluminum product manufacturing is conducted based on technical quality regulations. A total of 9 branches have been developed for the audit of the production system, but not all of them specifically relate to the production lines. During the audit, it is important to look at the following bottlenecks:
- First, it is necessary to ensure that the required equipment for production has indeed been implemented at the enterprise. This includes not only the machines or equipment themselves but also tools, auxiliary fixtures, and consumables.
- The equipment must be kept in good working condition. Work is planned for maintenance, system calibration, and repairs.
The analysis of efficiency also covers auxiliary points related to the quality of production lines. Even if the equipment is functioning properly, there may still be issues with the measuring instruments used in the technological operations. There are requirements for raw material control. The personnel involved in the work are also checked for qualifications and the required skill levels. The sanitary and hygienic conditions of the staff's working environment must not violate established standards.
Modern technologies in aluminum production
If an aluminum manufacturing company does not update its equipment and implement new ideas, it will stagnate in its development. Competitors will push them out of the market. Modern aluminum technologies include die casting and pressure casting. The use of dies can be multiple, which meets current demands, where scaling and automation are often necessary. The technology of pressure casting can also be easily automated, where properly selected equipment is capable of reducing the filling time of dies. Cost reduction is achieved by reducing raw material consumption and by decreasing finishing operations.
Successfully implemented innovations in production, which can already be seen in some enterprises, often include the process of modernizing electrolysis. The production process is being made safe for the environment. Modern electrolyzers with capacities of 400 and 500 kA are being produced, but previous generations of installations are also being upgraded.
Methods for Optimizing Work Processes
If an aluminum products manufacturing company has ceased to be profitable or to withstand competition from other players in the market, it is necessary to seek approaches to rethink the work process. If a crisis has arisen or there is an understanding that it's time to move forward, then it's necessary to work on the following points of the lean manufacturing concept:
- Evaluate current costs, and eliminate inefficient processes in production.
- Study and, if necessary, change the allocation of resources. Analyze the effectiveness of working with distribution channels.
- Change the quality of the produced goods, for example, improve the production process or adjust the marketing strategy.
- Automation of production is also important, and it should be implemented where there are already modern and proven solutions.
The systematic elimination of losses in the enterprise producing aluminum products also involves working with the staff. It is important to establish management and organize the work of employees correctly.
Training and motivation of personnel
Completely automating an aluminum products manufacturing enterprise is utopian, so personnel will still be present. His main motivation is the systematic improvement of working conditions. It's not just about a high salary, although it should be brought up to market level or higher if the budgets allow. The system of rewards and bonuses for performance always works well. Labor productivity improves when employees feel comfortable and safe at their workplace. This question often touches on the need to upgrade outdated equipment, which sometimes is physically incapable of performing certain processes quickly.
Improving qualifications should also be part of the company's plans, as a skilled workforce performs the same tasks faster, with better quality, and with a lower defect rate. But staff training sometimes does not show any results if the management system is not well established. It is necessary to delegate clear tasks to the staff and also to monitor the progress of their completion.
Case study: a real example of successful optimization
An example of optimization can be found in relatively recent times when in 2017 the Schlote group opened a new machining facility in Harzgerode (Germany) for processing one type of pressure-cast automotive aluminum—clutch housings. There, it was possible to apply automation experience, allowing for the production of 4,000 units per day. The staff works around the clock, but there are options to expand production to full weekly cycles.
The case study in this instance covers not only automation but also the extension of the lifespan of specific working tools, particularly deep drills. Engineers at this company have developed a tool using a carbide drill and a polycrystalline diamond tip on the cutting edge.
Conclusion and Prospects for Aluminum Production Optimization
The future of aluminum production will be focused on improving automation processes and increasingly reducing the reliance on manual labor. The analytics of processes will improve, where properly configured intelligence will quickly identify bottlenecks in production and suggest solutions and optimization strategies. The development prospects will also be directed towards ecological responsibility, reducing the negative impact of the enterprise on the environment, and recycling raw materials. New eco-friendly metal processing methods will reduce several cost items in such enterprises, including waste disposal costs in the production of aluminum products.
