8/26/20 - Zoro Staff
Keeping production lines running is essential to every manufacturer. The causes for downtime include breakage and malfunction of tooling or parts. However, you can minimize these issues with additive manufacturing. It’s a smart approach, especially when tooling is the concern.
The Real Cost of Downtime
If you have a line down, then it’s costing you money. Sometimes it's hard to determine the root cause, and that can lead to unknown losses. An estimate for factories is that they lose 5 to 20 percent of their productivity due to downtime[1].
Equipment malfunction is a leading cause. Most manufacturers don’t have insight as to when equipment needs maintenance. That leads to sudden failures, bumping your production offline.
Time is money in the industry, so having a backup plan for these challenges is vital. The replacement for tooling or parts may not be quick. That’s especially true right now: supply chains are in chaos due to the pandemic.
Enter additive manufacturing.
What Is Additive Manufacturing?
Additive manufacturing describes the technology and processes used to construct 3D objects. It uses a layer upon layer approach to materials. You can print with plastic, metal, concrete, or other substances.
Additive manufacturing requires 3D modeling software (such as CAD), machine equipment, and the material. The computer reads the CAD sketch and then begins to lay down the layers.
Because it’s a quick process, you can print the part you need and carry on with production. By using it on an on-demand basis, it provides you a safety net when lines go down.
Reduce Costs and Downtime
Manufacturers control tool design and availability. That often puts you in a precarious position. Additive manufacturing provides a solution you control. You can consistently create tools with 3D printing. In the end, you’ll save overall on replacement parts and ensure that downtime is minimal.
Replacement parts and tooling are certainly part of your budget. However, you don’t control the market. Prices can spike, and obtaining the parts may become harder.
Obtaining a 3D printer and materials is an initial investment, but it’s one that can pay off. You aren’t making molds, so that cost is off the books. These printed parts allow you to manage how you stock and when you stock, saving you further.
Emergency Spare Parts
Do you have an abundance of spare parts? Probably not. This may be due to availability or lack of storage space. While you want to maintain your inventory[2], sometimes it’s not possible.
While you wait on spares, print the part you need. It may not be as robust as the manufacturer’s part, but it will do the job short term. It’s a good idea to have a printed replacement on hand for all equipment.
Then when the spare part comes in, you can switch it out. Keep your printed copy for the next emergency.
3D Printed Parts Can Fill the Gap When OEMs Stop Making Them
For cost reasons, original equipment manufacturers (OEMs) stop making certain parts. It doesn’t mean the machine is no longer usable. The OEM may be phasing out equipment that still works fine for your needs.
If OEMs no longer make your replacement parts, you could face substantial downtime and cost. It may force you to upgrade to the newest version. Another option is to find a secondary source. These specialty shops are expensive. You’ll also have to buy in bulk and pay extra for the setup.
Neither of these is a great solution. You can continue to use your equipment by producing 3D parts. If you expect to keep it for another few years, you can continue to make consistent parts. Then you can upgrade on your schedule. This strategy helps you balance your capital investments to grow your business.
Low-Quantity Runs
3D printers can produce as little as one part. You can make as few or as many pieces as you need.
With this capability, you can store a greater variety of replacement parts at your location. This may be a pain point now since you must order replacement parts in large quantities. You don’t know which part may break, so you can’t guess what inventory you need.
Leveraging additive manufacturing allows you to print the most vital parts. You could determine this by maintenance records. With this data, you can then decide what parts to keep on standby.
Find 3D Printer Materials at Zoro
Zoro is glad to provide an array of 3D printer materials. We understand the needs of manufacturers and the replacement part ecosystem. Check out our stock of items today[3].
[1] https://www.isa.org/intech-home
[2] https://www.zoro.com/3d-printer-materials/c/9858/
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The product statements contained in this guide are intended for general informational purposes only. Such product statements do not constitute a product recommendation or representation as to the appropriateness, accuracy, completeness, correctness or currentness of the information provided. Information provided in this guide does not replace the use by you of any manufacturer instructions, technical product manual, or other professional resource or adviser available to you. Always read, understand and follow all manufacturer instructions.