Doubling Down on Automation: How Michigan Company Achieved Rapid ROI

CHALLENGE

A Michigan job shop struggled to maintain production and keep popular products in stock, leading it to seek a simple automation solution for its manufacturing process.

SOLUTION

The company implemented an AWR machine tending robot as a standalone cell, requiring additional training for operators who initially expected the system to run unattended.

RESULTS

The automation cell doubled profit sharing in the first year with a 9-month ROI, enabling continuous production and ultimately the purchase of a second robot cell.

A small Michigan-based manufacturing company, known for producing the highest-quality products in the world, serves DIYers and small businesses in the outdoors industry.

Struggling to maintain production and keep its most popular products on the shelf, the Michigan job shop began extensive research for a CNC automation solution. Needing technology that was easy to manage and operate, found a simple automation solution that didn't require an automation expert.

Initially, the CNC machinery and automation were not blended for the current production line, and instead, the AWR machine tending robot was introduced as a "standalone" cell. At first, there was a misconception that the robot unit would run without an operator. Therefore, training the shop floor about the required maintenance and procedures to operate the automation unit took time compared to their current understanding of CNC machining practices without automation.

Once fully integrated, the AWR machine tending automation cell increased production by doubling its profit sharing in the initial year. For instance, manually loading parts is quicker than the automation system. However, the machine tending robotic unit runs continuously, and its output equates to manually loading machines with two operators at the end of the week.

Overall, purchasing an automated CNC robotics unit has increased the company's ability to manufacture bulk orders of its high-demand products, while laborers can focus on customized parts. Beyond improving efficiency and cutting lead times, the numbers speak for themselves—"just for the automation. Our ROI was achieved in 9 months." The results led the company to purchase a second machine tending robot and build another cell to its operations. Lastly, the company advises, "Do not sacrifice quality to save a small percentage on the total project cost of implementation,". The company's commitment to quality over cost savings became its foundation for sustained growth and competitive advantage.

Doubling Down on Automation: How a Michigan Manufacturer Achieved Rapid ROI and Expansion

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