Manufacturing plants in India have traditionally relied on manual labour for various production processes due to the low cost of labour. However, this reliance can lead to inefficiencies, delays and unidentified losses, as well as various other issues. These issues could be due to human factors such as fatigue and miscommunication, machine factors such as interoperability problems and breakdowns, or system factors such as a lack of a centralised data system.
Replacing Manual Processes with Low-cost Automation
Low-cost automation (LCA) could be a practical solution for improving product quality and addressing other issues related to manual labour, such as low productivity. This involves implementing affordable technologies such as retrofitted conveyors and sensor-based quality checks, which streamline processes with minimal disruption and rapid return on investment.
By adopting LCA, it automates repetitive and manual routine activities to free up manhours. Some options even allow micro or small firms to access automation without heavy upfront capital.
With over 30 years’ experience delivering tailored solutions to global clients, including manufacturers, Renoir has implemented the following tried-and-tested, low-cost automation solutions:
1. Implement Active Management of Tool and Equipment Logistics and Availability
This solution involves implementing a power tool audit system to track usage and inventory. Our experience has shown that this system is effective, leading to an increase of power tools being repaired and distributed correctly, which has contributed to a 60% increase in workforce productivity.
Other systems can also be implemented to ensure that materials, equipment and resources are allocated correctly. Improving planning and task scoping ensures that no job commences without adequate preparation.
Cost savings through operational efficiency for manufacturer
Paper mill cuts material loss by 300% with maintenance planning
Cost savings through operational efficiency for manufacturer
Paper mill cuts material loss by 300% with maintenance planning
Ready for a change in your organisation?
2. Developing Scientific Manpower Planning and Allocation Tools
This solution focuses on eliminating inefficiencies and freeing up man-hours by replacing traditional, subjective staffing methods with automated workload management. A Manpower Calculator Tool could be developed to quantify the current and forecasted workload for different roles and functions.
This tool enables managers to allocate manpower more effectively, balancing the workload across their regions or departments without the need for additional recruitment. We have successfully helped a pharmaceutical manufacturer reduce their headcount by 9% at one of their manufacturing facilities.
3. Standardisation and Automation of Planning, Scheduling, and Setup Processes (SMED)
Standardising tasks and controlling the flow of materials and production can address the shortcomings of a manually driven system. For instance, manufacturers can use Single Minute Exchange of Die (SMED) techniques to reduce machine changeover times systematically. Meanwhile, updated bills of materials can streamline material planning, and shop floor product tracking systems can ensure that the right materials are available when needed to prevent line stoppages.
Defining and adhering to precise standards suppresses the variability caused by human factors and miscommunication. Implementing SMED automates efficiency gains in physical setup by enforcing standardised procedures, converting manual ‘internal’ activities to ‘external’ ones and providing each shift with measurement tools to track progress.
Low-cost automation is not a response to labour shortages. It is a strategic approach to achieving the precision, speed and quality required to compete on a global scale. By leveraging this advanced technology, you can propel your firm and the country into becoming a high-value, high-productivity global superpower.
Renoir has three decades of experience in tailoring solutions for companies in a wide range of industries. We have helped many businesses substantially improve their process controls, productivity and efficiency.
Automate Smarter, Grow Faster with Low-Cost Automation
