Which system is used for manufacturing product with very high demand rates and volumes

What Is High-Mix Low-Volume Manufacturing?

High-Mix Low-Volume (HMLV) Manufacturing, also referred to as make-to-order manufacturing, is the process of producing a high variety of products in small quantities. This production method is commonly used to manufacture unique and more complex products with specific quality requirements. 

High-Mix Low-Volume vs Low-Mix High-Volume Manufacturing:

HMLV manufacturing is the exact opposite of Low-Mix High-Volume (LMHV) manufacturing, which executes large volumes of product but with little-to-no distinction between the goods. This method of manufacturing was very popular for many decades as the consumer’s market demand started to increase. But over the years, the industrial sector has since evolved to manufacture products with maximum efficiency and high quality. Goods that were once considered high volume such as vehicles or appliances, are now custom made and tailored to customers, thus, are created in HMLV production. 

Companies that are looking to optimize operations are typically looking at lean manufacturing techniques, such as root cause analysis, run to target manufacturing, or total productive maintenance. Most of these methods utilize high volume production processes. However, low volume manufacturing businesses are more volatile because of the increased variation of products/services. This is why businesses improving operations in high-mix low-volume must adapt lean manufacturing practices when applied to this environment. 

What Are the Benefits of High-Mix Low-Volume Manufacturing?

• Improved customization of products
• Increased responsiveness to customers
• Cut costs as a result of less inventory in storage

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What Are the Steps to Improving Operations in High-Mix Low-Volume Manufacturing?

HMLV manufacturing requires constant changes in jobs, materials, and machines. With a limited number of production lines and a large variety of product requests, operators working in HMLV environments must constantly change scheduling of jobs and materials,  which can often lead to errors and inconsistency in products. Here are four steps to improving production operations in these environments. 

1. Optimize flow – the first step in optimizing operations in low volume manufacturing is to create a smooth product flow, despite the many product variations. 
2. Create a plan – once you create an effective flow, or plan, aligning on a product flow plan enables manufacturers to better predict outcomes and eliminate failures in production.
3. Improve communication between employees – an open environment provides staff, from every department in the company, the ability to check the status of production and alert operators accordingly. 
4. Uphold flexibility – every aspect in a factory, from inventory to machines to scheduling of staff needs to remain flexible in order to handle the constant changes needed with HMLV manufacturing. 

Deploy a real-time shop floor control software – it’s crucial for maintaining support across all departments 24/7. With smart notifications and one centralized platform to access all jobs, statuses, and KPIs, there is less error in communication and increased productivity amongst staff.

WHAT IS HIGH-VOLUME MANUFACTURING?

High-volume manufacturing is exactly what the name implies — producing large numbers of an identical part or product in one run.

While the term can refer to any manufacturing process, liquid silicone rubber (LSR) injection molding is one of the most common methods of high-volume production. LSR is a durable and flexible material with excellent temperature resistance. As a result, it is an ideal choice for a wide range of processes:

• Single-shot injection molding: Injection molding involves injecting heated LSR into a mold along with a curing agent that causes it to harden. It is a fast way to mass-produce simple parts with a high level of accuracy.
• 2-Shot injection molding: 2-shot injection molding, or multishot injection molding, is another type of injection molding that involves the use of two or more thermoplastics at once, fusing them together in the finished component. This allows for more complex manufacturing with fewer additional assembly operations.
• Overmolding: Overmolding involves molding an LSR component onto a metal or plastic part. Like 2-shot molding, it allows manufacturers to produce more complex parts on a mass scale.

Injection molding is a versatile, flexible process suitable for a wide range of industries and applications. Below, we’ll look at a few reasons why high-volume injection molding manufacturing might be a good choice for you.

HIGH-VOLUME INJECTION MOLDING PRODUCES ITEMS FASTER

High-volume manufacturing is the fastest way to turn around a large order of parts or products. This means you get your product to market faster, allowing your organization to stay on the leading edge of innovation. In a competitive economy where manufacturers are continually introducing new items, the time you’ll save with high-volume manufacturing can set your organization up for success.

HIGH-VOLUME INJECTION MOLDING REDUCES YOUR OVERALL COSTS

Another benefit of high-volume production is that it is an economy of scale. Although there are expenses related to the initial tooling and prototyping stages, the low cost per unit easily offsets them in a large production run. LSR molding parts exhibit a high degree of uniformity, too, which means fewer rejections due to quality concerns.

If you’re wondering whether or not LSR injection molding is the right choice for your project, let the SIMTEC Silicone Parts team prepare a detailed cost-benefit analysis.

WORKING WITH SIMTEC

SIMTEC is a longstanding expert in high-volume production of LSR parts for automotive, medical and other industries. We regularly support Fortune 100 and other major businesses with their manufacturing needs. Based in South Florida, we are ideally situated to fulfill orders for clients across the country and internationally. Browse our website to learn more about our expertise or contact our office directly to request a quote.

What is high volume manufacturing?

What method is usually used by manufacturing companies when there is a need for big volume of products?

Which production processes are used for high volume production of discrete parts?

Which system is characterized by high volumes of standard products?