Automation in Manufacturing: PMMCO’s Journey Toward Efficiency and Innovation
Automation in manufacturing has been transformative for the industry, and at Progressive Metal Manufacturing Company (PMMCO), we’ve embraced automation to deliver better results for our customers.
But our automation journey didn’t happen overnight. Our team has spent years finding the right balance between automated and manual processes. Today, we’re proud to announce that this trial of learning and continuous improvement has been worth it; our current automation initiatives have increased efficiency, precision, and cost savings exponentially.
Allow us to walk through our journey in automation from the eve of the new millennium to today.
Where We Started: Dipping Our Toes in Automation
Our journey in automation began in the late ‘90s when we introduced our first robotic welding system. Our team identified the best-fit job for the robot, our highest-volume project, and partnered with one of our vendors to build a custom welding cell. Remarkably, that same robot is still operational today, consistently producing high-quality parts for that very same customer! This successful implementation highlighted the potential for automation to enhance our capabilities.
However, with proven long-term success comes the occasional letdown, as not every automation investment has delivered immediate results. One early system we adopted did not adequately meet our productivity expectations, causing us to return to the drawing board. Despite the trials and occasional tribulations, the PMMCO team never backed down. Instead, we learned from these experiences, adopting proven automation solutions tailored to our specific needs that would deliver an impressive return on investment and align with our existing manufacturing processes.
Automation Solutions at PMMCO
Strategically Automating Our Laser Cutting Services
PMMCO is currently on our third generation of laser automation systems, which have significantly improved efficiency and output. With our unique approach to laser cutting, we prioritize processing sheets of metal as soon as they are manufactured. This method ensures faster production times and reduces the need for intermediate storage. Recognizing the advantages, the industry has evolved to align with our forward-thinking approach, and modern robotics are now capable of picking and stacking parts directly off the laser systems. This real-time processing enhances efficiency and maintains the high standards our customers expect in our precision fabricated components.
While automation has undoubtedly advanced our laser cutting services, we understand that not all laser work should be automated. Approximately one-third of our laser cutting projects remain manual, allowing us to handle unique materials like diamond plate and expanded metal that aren’t suitable for automated systems. Maintaining this level of flexibility ensures that we can continue to meet our customers’ diverse and specific needs.
Leveraging Robots in Our Precision Welding Services
With five robotic welding cells in operation, the PMMCO team strategically selects the parts that are best suited for automation. These robots excel at high-volume, repetitive welding tasks, offering a production speed at least twice that of manual welding.
However, certain parts are better handled by skilled human welders, including:
Complex projects that require the adaptability and craftsmanship that only a human can provide
Low-volume work, as the time to program the robot may not be worth the potential time or cost savings associated with this service
By balancing robotic and manual welding services, we ensure our customers receive the high-quality, cost-effective solutions they expect from us.
The Value-Add of Automation in Manufacturing
PMMCO’s investment in automation delivers significant advantages for our customers, including:
Lower costs: Automated systems reduce production time and labor costs, so we can offer more competitive pricing.
Enhanced quality: Robots provide consistent and precise results, ensuring welds and cuts meet stringent quality standards.
Increased efficiency: Automation allows for faster production cycles, enabling us to meet tight deadlines and scale production as needed.
As we integrate advanced automation technologies, we remain committed to finding creative solutions that fit our customers’ unique requirements. At PMMCO, we leverage both automated and manual processes to deliver custom fabrication services that meet the highest quality and productivity standards.
Interested in learning firsthand how automation in manufacturing can benefit your next project? Request a quote to leverage our expert solutions!