Mastering High Mix, Low Volume Manufacturing with Flexible Automation
Updated: 2 days ago
High mix, low volume (HMLV) manufacturing means building many different products in small batches, with runs of a few dozen to a few hundred pieces and a changeover every time the part changes. Fixed automation loses money here because the tooling never pays for itself across a short run, and every changeover is downtime.
The automation that works in HMLV is flexible by design. The test for any piece of equipment is the same. How fast does it change over, and can the operator do it from a recipe, or does it take a skilled engineer?
The decision guide, updated as the lines change, is How to Automate High-Mix, Low-Volume Production Without Betting the Shop. This post walks the five manufacturers' lines that make it work.
Which automation works for high mix, low volume?
In practice it comes from four kinds of equipment.
Flexible feeders that switch parts with a recipe instead of a retool
Modular conveyors and framing that reconfigure as the line changes
Quick-change end-of-arm tooling, so one robot serves many products
Presses with programmable recipes and an audit trail per part number
A dedicated bowl feeder or a hard-tooled line still wins on one part at high volume. If you run one product all year, buy the dedicated system. The rest of this guide is for everyone else.
We represent flexible automation lines from several manufacturers, including mk North America, Zimmer Group, Asyril, FANUC, and Omron, and we help put them together into a cell that changes over fast, whether it is built by your team, your integrator, or with our specialists alongside.
Five Pillars of Flexible Automation
Let's explore how five innovative companies are revolutionizing HMLV manufacturing, and how M6 Revolutions brings these technologies together into 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, covering 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 strong fit 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 used 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 uses 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 combined into a cohesive system. At M6 Revolutions, our job is helping you assemble that system from lines that already work together.
One production cell these technologies add up to:
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 help you put a whole solution together around your specific HMLV challenges, from component selection through startup. Here's how we put these technologies to work, along with the full 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 Sourcing: From FANUC robots and mk North America frames to Omron's HMIs, PLCs, sensors, and more. One conversation covers every major component, and the pieces are proven to work together, whether your team or your integrator does the build, with our specialists alongside.
Smooth Integration: All components are designed to work together, simplifying your automation architecture. We help you check that the pieces talk to each other and to the systems and workflows you already run.
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. Here's what that flexibility buys:
Dramatically shorter setup and changeover times
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 a challenge, and it's an opportunity to gain a competitive edge.
At M6 Revolutions, we're passionate about helping manufacturers work through this shift. 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.
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