When to install a new line vs an individual machine
Every plant must have production lines which function optimally to deliver results. It means having the right equipment across your line, compatible with your product type and in keeping with your goals.
However, change is needed when introducing new projects into your plant or improving results. The question is whether you need to invest in a whole new line or upgrade the solutions that make up your existing line.
This guide explores the instances where you need to install a new line into your plant and when you need just a single machine.
When you need a new line
Introducing a new line into your plant means starting almost from scratch. You will source the various components of the line (including weighers, inspection systems, conveyor belts and other machinery) before installing them into your plant to fulfil the intended processes.
There are several situations when you might require a new line. One of the most common is if you are introducing a new project or contract into your plant. Typically, this requires specific machinery to meet the requirements of the product, especially if your existing lines aren’t compatible. You will create suitable conditions that generate quality output through the new line.
The line will form a part of your project plan, allowing you to identify precisely which solutions you need to meet targets.
Another instance where you might choose to install a new line is if your existing lines are no longer fit for purpose or need to be re-optimised. A single machine might not boost results sufficiently if the issues are particularly complex.
By installing a line, you will benefit from new more efficient systems, which, when brought together, will allow you to fulfil production goals better and improve output.
The benefits of a new line
There are many advantages to installing a brand-new line into your plant.
Firstly, every piece of equipment will be in good working condition and more efficient. Over time, systems are subject to wear and tear, which might impact the functionality of your whole line.
A new line will be tailored specifically to the needs of your products and plant. Rather than introducing systems to an existing line, you ensure that every component in your line works in harmony, allows for better end-to-end processes.
A line will be customised to meet your needs, allowing for more flexibility than when a single machine is replaced which may mask the real issues in your line.
When you install a new line, it will be purposely designed and installed so that the different components feed into each other effectively and efficiently. Everything will work as a well-oiled machine without the risk of incompatibilities that derail performance.
If you source the line from one place, it is even more likely that the components will be compatible. You will also be able to obtain a package deal across the line, which could include building, testing, commissioning and maintenance at a competitive price.
Finally, the replacement of your line will allow your plant to seek a broader range of contracts and opportunities.
When you need an individual solution
While the introduction of a line is needed in some circumstances, there may be times when a single machine (such as a weigher or inspection system) will suffice.
One such instance is if just one part of your line has requires replacement or an upgrade. It might include if the machine has started to function poorly, which has a knock-on effect on your results. If the rest of your production line is in good working order, you will likely be able to change the underperforming part – but remember to make sure any system you purchase is compatible with the rest of your line.
Alternatively, if your needs have changed slightly but not enough to warrant a whole new line, adding or switching a machine may be the option. For example, if you are looking to improve productivity, you might swap to a weigher with a higher capacity.
If you need to fulfil another function (for example, introducing packing or inspection), there is the option to add an appropriate system onto the line. Again, planning will be crucial to ensure it fits into the line without causing disruption and that your requirements are addressed.
The benefits of individual solutions
It is understandable that a plant may purchase just one machine rather than an entire line.
The main advantage is cost. Sourcing a new line is a substantial investment, especially if you have multiple solutions you need to incorporate. Buying one system is cheaper.
It’s particularly ideal if there is just one machine causing you issues, allowing you to boost results without having to reengineer the entire line.
It can also still be efficient in upgrading parts of your line by allowing you to introduce new functions or re-optimise specific parts. If you know that most of your line is fit for purpose, a single solution might be all you need to meet new output targets or revitalise performance.
However, when installing a machine, it is critical to check that it is compatible with the rest of the line. If it isn’t, you risk poor results threatening your reputation.
Prolonging the life of your production line
Whether introducing a new line to your plant or optimising existing ones, it is crucial to keep them working optimally and consistently. Undertaking routine maintenance is integral to prolonging the lifespan of your machinery and preventing disruption.
Having a service contract is crucial, as it gives you access to expert support. Depending on your agreement, it will cover areas such as calibration, checks, parts replacement, and repairs. It will allow you to spot issues ahead of time so they are rectified and able to function correctly.
If you are conducting repairs in-house, aim to build an inventory of genuine spare parts sourced from the machinery manufacturer. Using genuine parts when your machine requires them will bring systems back to full functionality and deliver long-lasting repairs.
It’s also recommended to train your production line operatives, so they know how to use the equipment correctly. This prevents user errors leading to machine breakage or wear-and-tear. It will also improve the chances of you getting your desired results.
All the above will protect your production line from damage and extend its lifespan, meaning there is less need for new lines or solutions.
Yamato’s support
There are circumstances where you need either a new line or a single solution. Knowing when each is appropriate is crucial to managing your budget whilst promoting positive results.
If you need a new line, it’s important not to cut corners with a single machine, as it won’t give you the desired output. If you only require a minor upgrade to your existing lines, a single solution will suffice – but remember to ensure it fits into your plant effectively.
At Yamato, we work with manufacturers worldwide to deliver solutions and high-performing lines to facilitate their projects. We assist you through the process, from build to installation, so you your line is optimised to meets all your goals and offers an excellent return on investment.
We offer individual machines to revitalise your existing line, alongside support such as service contracts, training and spare parts.
Get in touch with a team member today to discuss your needs.