When most people think of automation in manufacturing, they imagine high-volume automotive production lines with robots working 24/7, cranking out tens of thousands of identical parts. That image isn’t off-base; in fact, many U.S. automakers pioneered the use of automation and robotics on the shop floor.
But today, automation isn’t just a means for mass production. In fact, at Reata Engineering, we’ve found that automation offers just as many benefits in low-volume production.
Why People Think Automation Only Works for High Volumes: Understanding This Common Misconception
The belief that automation only makes sense for large quantities comes from legacy systems. In the past, automating every single process required weeks of programming, extensive tooling, large teams of process engineers, and—as a result of all of these—added costs. For companies producing millions of the same part, that investment made sense. But for precision machine shops handling low-volume production, it wasn’t realistic. But that has changed.
How Automation Supports Low-Volume Jobs
Thanks to parametric automation systems, like those from our integration partner HALTER, setting up a robotic job today is fast, repeatable, and intuitive. For example, our robot asks about 10 basic questions before it gets to work related to:
- Part length
- Finished size
- Operations
- Offsets
- And so on
Our team can typically create a working robotic program in about 30 minutes and prove it out in another 30 minutes. That’s certainly a far cry from the hours of programming that were commonplace in the past.
We often begin quality inspection on a prototype while we set up a robot, so that by the time the part is approved, the automation is ready to go. Then we run the job overnight and, just like that, a job that might have taken two days now takes one. This model of setting up during the day and running the job overnight lets us double throughput and keep lead times competitive.
The Value of Automation in Low-Volume Production
Maximizing Uptime with High-Mix Parts
Our team runs nine lights-out machining centers capable of producing a wide range of components, from medical components the size of a fingernail to aerospace machining parts that require both hands to lift. These machines don’t sit idle between jobs. Instead, we keep spindles turning by strategically slotting in low-volume, high-mix orders using 5-axis and multi-axis machining equipment.
Contrary to assumptions from the past, automation is actually ideally suited for low-volume, high-mix environments as it allows our team to maximize spindle time and increase productivity without sacrificing quality or lead time.
Increased Efficiency Through Smarter Processing
Many shops install a robot and call a procedure “automated,” but true success in automation happens when a shop takes every step of the process into account. We’ve invested in learning how to control the many variables involved, such as tool wear, part handling, and inspection requirements, among others, so that we can run parts of all quantities with confidence. This results in:
- Faster setups
- Lower labor costs
- Reduced lead times
- More consistent quality
What does this mean for our customers? They directly benefit, as we pass these value-adds directly to them!
Automation as a Tactic in Recruitment and Retention
The modern workforce wants to work with the latest tools. That means automated capabilities aren’t only efficient; they’re attractive to prospective and current team members alike. It comes as no surprise that employees take pride in working for a forward-thinking shop. So, automation and other cutting-edge technologies support talent acquisition and employee retention efforts at Reata. It’s an added bonus, and one we don’t take lightly!
Choose Reata for Your Low-Volume Work
With the right equipment, the right people, and the right process, automation delivers real results, even on low-volume production jobs.
Let us show you how our automated processes can reduce your lead time, improve your quality, and lower your costs. Request a quote from Reata today!