Mastering High Mix, Low Volume Manufacturing with Flexible Automation

High mix, low volume (HMLV) manufacturing is a complex challenge that an increasing number of manufacturers are facing across industries. From automotive and aerospace to consumer goods and electronics, the need to efficiently produce a wide variety of products in small quantities is becoming more pressing. Traditional automation solutions, designed for predictable, high-volume production, often struggle to meet the demands of HMLV environments.

At M6 Revolutions, we've taken it upon ourselves to help manufacturers overcome the challenges of HMLV production. Our approach is unique: rather than relying on a single vendor or solution, we integrate the best flexible automation technologies from multiple industry leaders, including mk North America, Zimmer Group, Asyril, FANUC, and Omron. Combining these tools into customized, adaptable solutions enables our clients to master HMLV manufacturing and stay competitive in their markets.

The HMLV Challenge

Before we dive into solutions, let's understand the challenge. HMLV manufacturing is characterized by:

• Production of a wide variety of products in small quantities

• Frequent changeovers and reconfigurations

• Need for quick adaptation to market demands

• Balancing efficiency with flexibility

Traditional automation, designed for high volume, low mix environments, often falls short in these scenarios. This is where innovative, flexible automation solutions come into play.

Five Pillars of Flexible Automation

Let's explore how five innovative companies are revolutionizing HMLV manufacturing, and how M6 Revolutions integrates these technologies to create powerful, adaptable solutions:

1. mk North America: The Backbone of Flexible Automation

mk North America's modular conveyor and aluminum-framing platform brings nearly 60 years of German engineering to HMLV environments. Here's how:

• Modular Design: More than 250 standardized aluminum profiles and welding-free connectors let production lines reconfigure for different products, adapt to changing part sizes and shapes, and scale up or down without custom fabrication.

• Conveyor Breadth: Twenty conveyor types — flat belt, modular plastic belt, chain, and pallet-handling VersaMove — cover loads from 33 to 2,200 pounds at speeds from 10 to 400 feet per minute. One platform handles nearly any product mix, including stainless washdown-ready builds for food and pharma.

• Built to Reconfigure: Conveyor sections, machine bases, and guarding all come from the same profile system, so a line change reuses existing hardware instead of scrapping it — the staged, low-risk path to flexibility.

2. Zimmer Group: Masters of Adaptable Gripping

Zimmer's innovative gripping solutions are a game-changer for HMLV production. Here's why:

• Quick-Change Grippers: Switch between product types in minutes, not hours. Automated tool changing reduces downtime, and standardized interfaces allow for easy integration with various robots.

• Adaptive Gripping: One gripper handles various part geometries with adjustable gripping force for delicate to robust parts. Sensor integration enables real-time adjustment.

• Robot Agnostic: Compatible with a wide range of robotic arms from major brands. Flexibility to upgrade or change robots without replacing end-of-arm tooling.

3. Asyril: Flexible Feeding for Diverse Parts

Asyril's flexible feeding systems are revolutionizing part handling in HMLV environments:

• Vibration-based Flexible Feeders: Efficiently handle a variety of part shapes and sizes without mechanical redesign when changing parts. Gentle handling for delicate components.

• Quick Changeover: Minimal downtime when switching between products. Software-driven part recipes for easy switching and self-learning algorithms optimize feeding parameters.

• Easy Integration: Similar to Zimmer, Asyril has made it a priority to remain robot agnostic. Open interfaces for easy communication with factory systems and compact design for flexible placement in production cells.

Real-World Application: One of our customers leveraged Asyril's Eye+ Studio to program hundreds of different part recipes for their robotic pick and place system. Each part took under 15 minutes to program, enabling rapid adaptation to new products. This system is powered by an Omron HMI and PLC, and utilizes an Omron SCARA robot for pick and place operations.

4. FANUC: Versatile Robotics for HMLV Environments

FANUC's robotic solutions provide the flexibility and precision needed in HMLV production:

• Extensive Robot Portfolio: From compact SCARA and delta robots to heavy-payload six-axis arms, covering all HMLV needs. The CRX collaborative line supports human-robot cooperation in flexible cells, backed by the largest installed base in industrial robotics.

• Tablet Programming: The CRX line's drag-and-drop tablet interface enables quick task changes, reduces reliance on specialized programmers, and allows on-the-fly adjustments for product variations.

• ROBOGUIDE Simulation: Offline programming and simulation for efficient cell design. Virtual commissioning reduces physical setup time and makes it easy to replicate successful cell designs across multiple lines.

5. Omron: Tying It All Together

Omron's automation components and systems provide the glue that holds these flexible systems together:

• PLCs and HMIs: Powerful controllers and intuitive interfaces for smooth system integration and user-friendly operation. Easily adapt to changes in production requirements.

• Sensing and Safety: Advanced sensors for part detection, quality inspection, and adaptive control. Safety components ensure smooth human-robot collaboration in flexible environments.

• Machine Automation & Industrial Networking: Servo systems, machine controllers, and industrial network solutions to tie all components together for a unified, adaptable system.

The Power of Integration: Creating HMLV Powerhouses

While each of these technologies offers significant benefits on its own, the true magic happens when they're integrated into a cohesive system. At M6 Revolutions, we specialize in creating these powerhouse HMLV solutions.

Imagine a production cell where:

• A FANUC robot, mounted on an mk North America aluminum frame, provides precise and programmable motion

• The robot is equipped with a Zimmer quick-change gripper, allowing it to handle a wide variety of parts

• An Asyril flexible feeder supplies diverse components to the robot, automatically adjusting to different part types

• The entire cell is controlled by an Omron PLC and HMI, providing smooth integration and user-friendly operation

This combination offers unparalleled flexibility and efficiency for HMLV production, allowing manufacturers to:

• Quickly adapt to new product introductions

• Efficiently handle small batch sizes

• Reduce changeover times dramatically

• Improve overall equipment effectiveness (OEE) in mixed-model production

M6 Revolutions: Your Partner in HMLV Automation

At M6 Revolutions, we don't just provide individual components; we integrate complete solutions tailored to your specific HMLV challenges. Here's how we put these technologies to work, along with comprehensive offerings from partners like Omron:

• Tailored Solutions: We mix and match the best tools for your specific HMLV needs. Our expertise spans across industries, allowing us to bring best practices to your unique challenges. We consider your current and future production needs to create scalable solutions.

• One-Stop Automation: From FANUC robots and mk North America frames to Omron's HMIs, PLCs, sensors, and more. We handle the integration complexities, providing you with a turnkey solution. Our partnerships with leading vendors ensure you get proven components for every aspect of your automation.

• Smooth Integration: All components are designed to work together, simplifying your automation architecture. We ensure effective communication between different systems for optimal performance. Our solutions integrate with your existing systems and workflows.

• Future-Proof Systems: Easily expand or modify your setup as production needs change. Modular designs allow for incremental upgrades and additions. We provide ongoing support and upgrades to keep your system current.

The result? A highly flexible, efficient HMLV production line that can adapt to market demands at a moment's notice. Our clients consistently report:

• Reduced setup times by up to 80%

• Increased throughput in mixed-model production

• Improved quality and consistency across product variants

• Enhanced ability to respond to market changes and new opportunities

Ready to Revolutionize Your HMLV Manufacturing?

The world of manufacturing is changing, and HMLV production is here to stay. With the right approach and technologies, it's not just a challenge to overcome—it's an opportunity to gain a competitive edge.

At M6 Revolutions, we're passionate about helping manufacturers navigate this new landscape. We bring together the best in flexible automation to create solutions that are as adaptable as they are powerful.

Ready to take your HMLV production to the next level? Let's collaborate on creating a flexible, high-performance solution tailored to your unique needs. Want to talk through your application? Give us a call at 509-310-3584.