How Yamato supports your manufacturing project for premium results
There are many factors that deliver an excellent manufacturing project. Creating the processes and production lines that align perfectly with the requirements of your products are just the bedrock, coupled with the optimal conditions which will then result in high-quality output.
If you are introducing a new project into your plant or need to re-engineer the existing lines, you need to do everything right. This will unlock numerous rewards for your plant, including improved quality, enhanced safety, reduced costs and better efficiency.
Your goal is to bring optimised production lines to your plant, you may be asking what you should do to secure the best possible results. With manufacturers facing numerous obstacles this year, it’s vital more than ever that you understand the barriers to overcome and incorporate critical planning and support into your projects.
Yamato partners manufacturers requiring this assistance. We offer a wide range of solutions and services that drive performance, empowering plants across sectors and product types to access high-quality output and knock down obstacles.
In this blog, we explain in more detail how we work with you to implement projects that bring you outstanding results and long-term efficiency.
Planning
Building an optimised production line requires consideration of the criteria you need to fulfil and compatibility with the materials you will be processing. This enables you to create a production line with the right equipment to ensure high-quality output, meeting all the required standards. It will ensure efficiency across the line through appropriate solutions, reducing costs and improving productivity.
We work with you to understand the specific needs of your manufacturing project and translate your vision into a high-performing production line. This includes identifying the various tasks and equipment you need to incorporate to address your customers’ needs.
With your needs identified, we will pinpoint the solutions that will work best through the unique characteristics of every product you sell. This results in us identifying machinery that is entirely compatible with your product types, allowing easy processing that speeds up turnaround times and enhances hygiene, and bringing in best of breed partners.
We’ve worked with countless factories, giving us the expertise to know what works in each sector and the demands that commonly need to be accounted for.
The result is a production line wholly aligned to your requirements, enabling you to address customer expectations and drive quality.
With this effective plan, you can turn your project into a reality with confidence that all factors have been considered.
Provision of equipment
The next step of your project is accessing the equipment you need. As Yamato’s solutions cover a wide range of areas, including weighing, mixing, packing and product inspection, we provide many of the tools you need.
We offer versions of our machinery suited to different environments, enabling you to identify one that works with your products or needs. We tailor our machinery to your unique requirements, offering bespoke solutions for your plant.
If you aren’t sure what equipment you need, our expert sales team will take you through the available options and help you to find the best solution. We offer fast delivery, with many products in stock or built in our Leeds-based head office.
We will run trials with your materials and our equipment to ensure the desired results are achieved with the appropriate speed and accuracy before you install it.
Installation
Once you have planned your project, you need to build it. Part of your planning will involve considering equipment flow and at which stage different equipment/tasks sit. This makes the installation process more manageable, with a detailed understanding of how elements fit together.
Once installed, we work with you to commission it into your plant. This enables you to ensure each piece of machinery is efficiently installed and calibrated in an environment that allows for efficient production.
With your production line expertly planned and installed, you can now focus on driving results and generating output.
Data collection
Data monitoring plays an integral role in allowing you to maximise performance across production lines. In the age of intelligent manufacturing and industry 4.0, more manufacturers utilise data collection and analysis to access fuel results.
Many benefits will be unleashed by using data. Firstly, you are able to track the efficiency of your equipment and production line, enabling you to gauge and improve performance. Secondly, you can identify any issues ahead of time, helping you to make fast fixes and avoid significant disruption.
As we know the importance of performance monitoring, our equipment comes with the software to visualise and review production data. For more comprehensive data collection, we offer Yamato Stats, specifically designed to provide real-time analysis across your plant.
Using Yamato Stats, you are able to track individual lines, shifts, sites and products to get exactly the insight you need – including overall equipment efficiency, giveaway costings, auditing records and productivity information. Two-way communication works between the software and all of our Yamato products, enabling you to visualise data into meaningful reports across your entire plant.
We also offer a lighter version, which collects automated I/O data across your equipment, allowing you to flag issues and monitor efficiency. This means there is an option for every plant, budget and set of requirements while still maximising performance.
Training
To get the most out of your production line, you need to train your staff appropriately. This will encourage them to run processes correctly, fully understanding the functionality of the equipment they are using and the requirements of your output.
With this training, you will reduce the risk of disruption stemming from improperly-performed tasks and the resulting potential damage to machinery. This means you benefit from fewer machine faults, alongside better compliance and quality across your products.
It will also drastically improve safety across your workforce, in line with the Health and Safety at Work etc. Act of 1974.
We offer training across our equipment, sharing our expert knowledge with your staff to allow you to get the most from your production line. Training can be conducted on-site or at our Leeds-based facility and include product demonstrations, hands-on learning and valuable training materials to take away.
For those factories implementing one of our x-ray systems, we offer additional support, in the form of training your nominated Radiation Protection Supervisor to ensure compliance with ionising radiation regulations. We are able to assist you in appointing an external Radiation Protection Advisor, as required.
Servicing and repairs
With an accurately planned, expertly installed and optimised production line, you will be ready to start generating high-quality output for your project. However, during the course of daily operations, it’s natural for general wear and tear and other issues to occur, reducing the efficiency of your production line over time.
Due to this, maintenance of your equipment is essential to keep good conditions and consistently positive results. Without it, you risk production line faults that lead to substandard output and unplanned downtime.
By scheduling regular maintenance within your plant, you will keep everything operating smoothly and rectify any issues before they worsen.
At Yamato, we provide service contracts at various levels to maintain your production line.
Our standard contract allows you to access routine inspection of your machinery and re-calibration as required, so you may monitor the health of your production line and retain quality.
At the next level up, our full-service contract includes repairs and parts replacement as required, meaning that faults are fixed without unbudgeted costs.
Alongside our service contracts, we provide genuine spare parts for all our equipment, allowing you to build up an inventory of parts to address promptly any internal repairs as required. This cuts any downtime faced, allowing lines to get moving again quickly in the event of an unexpected breakdown.
All of our spare parts are backed by our warranty and rigorously tested so that you can be confident in their quality, with fast delivery and 99% availability across all our stock, making spare parts management simple.
Conclusion
There is plenty to consider to enable you to perfect your manufacturing project and deliver the best results. From knowing the specific requirements of your products to understanding how your new project coordinates with your existing production lines, a great deal of planning and thought is required.
Even once your project is realised, work will undoubtably continue to create optimal conditions and improve performance.
It is a huge challenging to undergo this process alone. Manufacturers will need to source appropriate equipment for their new projects that align with their production guidelines while also covering the areas of staff training, maintenance, analysis and so on.
Having external support from the right partner makes the process much easier and will enhance the results you experience. At Yamato, we assist you throughout the entirety of your project, from the planning stages to the installation of your equipment. Our services also cover the areas of data analysis, maintenance and repair, and training so you are able to optimise your processes and guarantee continually outstanding results.
If you have a project you are implementing or want to refine your existing production line to drive performance, we are here to help, whatever your needs may be.