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 Vention, Zimmer Group, Asyril, Yaskawa, and Omron. Combining these cutting-edge 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. Vention: The Backbone of Flexible Automation

Vention's modular industrial equipment platform is changing the game in HMLV environments. Here's how:

Modular Design: Quickly reconfigure production lines for different products, adapt to changing product sizes and shapes without major overhauls, and scale production up or down based on demand.
Rapid Integration: Reduce setup time from weeks to hours. User-friendly design software allows for quick iterations, and pre-integrated components ensure smooth assembly.
Cloud-Based Collaboration: Design and plan integrations in real-time, collaborate with team members remotely, and access a library of pre-designed modules for common applications.

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. Yaskawa: Versatile Robotics for HMLV Environments

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

Extensive Robot Portfolio: From compact SCARA to heavy-duty arms, covering all HMLV needs. Collaborative robots for human-robot cooperation in flexible cells and high-speed picking robots for efficient handling of varied products.
Smart Pendant: Intuitive programming for quick task changes. Reduces reliance on specialized programmers and enables on-the-fly adjustments for product variations.
MotoSim Touch: Offline programming and simulation for efficient cell design. Virtual commissioning to reduce physical setup time and easy replication of 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 Yaskawa robot, mounted on a Vention modular 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 leverage these cutting-edge technologies 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 Yaskawa robots and Vention 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 the best-in-class 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 at the cutting edge.

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.