The key to reach the highest level of producivity in mattress production: Automation
Save time, Save Money
Automation saves time and boosts the daily production capacity of mattress manufacturing companies. The work stations for manufacturing processes of mattress are full repetitive of tasks. So there is enough room for automation.
So before thinking about an automation every company needs to analyze their needs: daily production capacity, mattress models, mattress sizes. After analysisof this details a mattress production line needs to be designed to fully automate the production process of mattresses. Only in significant areas operator will be needed like mattress sewing or quality control.
Basically automation in mattress production means that the costs per unit will be reduced and daily production output will drastically increase.
The same idea since 1913. Transparent workflow through a line
Henry Ford installed in 1913 the first assembly line for automotive production.
He reduced the production time of a car from 12 hours to 1 hour and 33 minutes.
The main idea of mattress production lines is the same. But still many mattress companies are trying to use the technology before 1913 in the mattress industry.
They are assembling the mattresses in endless work stations. The sadest part is, that the mattresses are getting carried by hand between the different work stations.
When we would analyse the walking route of the employees from a bird’s eye view,
it will look like a spider which is making a web.
But the automation technologies are bringing this workflow to a different level and simplify the whole process of mattress production.
By using automated mattress production line it possible to track the whole production process in one line. On one side the raw materials are coming in, on the side the finished mattresses are coming out.
Elevate your productivity
Why wasting 4 minutes for a mattress if it is possible to produce it in 40 seconds?
If you’re spending less lead time for each unit, you are skyrocketing your efficiency of mattress production.
It is possible to design the production lines for every daily mattress capacity.
For sure it is not making sense to design a line for 30 mattresses/day.
At least 200 mattresses should be the daily production capacity to think about an automated line.
Safe enviroment & preventing back pain
Automated production lines for manufacturing mattresses prevent workers from dangerous work enviroment. The workflow is smoothly organised through a line.
There is no difficult walk needed between the work stations.
Also most important is the health of spine of your employees.
They will thank you for safeguarding them against this unnecessary moves in the production area.
Simply put, automation saves the health of the employees and prevents injuries in the mattress factory.
Quality is never an accident
How to eliminate returns of your mattresses?
The quality control of the manufactured mattresses before it leaves the mattress factory is the key to eliminate returns. Even the smallest untrimmed thread on a mattress will maybe cause an return of a mattress to the factory.
The quality control station is a standard in every mattress production line. So every defect will be dedected in this area before leaving the factory.
Automated lines extremely simplify the quality control process.
With the help of intelligent technology it is possible to easily lift, rotate and flip the mattresses to make quality control. The system enables the manufacturers to take appropriate actions to fix the quality error and identify bigger problems.
The competition never sleeps
Automated production lines for mattresses enables you to decrease lead times and cost-per-unit. This allows you to better compete on a local and global scale. If you can reduce your mattress and improve your quality it will eliminate your competition.
In the traditional manufacturing process you can never fully standarize workflows. How much a operator is spraying adhesive for each mattresses depends how he is feeling today and how good the weather is.
But with an automatic mattress glue line it possible to set up by three clicks how much adhesive the nozzles will spray to each mattress.
In this way you can easily standardize processes across the entire mattress production line.
Flexibility to produce many mattress models
Efficient mattress production by automated technology allows a full flexibility to switch the production quickly to different mattress models. This flexibility permits a faster reaction to the daily demand of mattresses. It takes only minutes to change the raw materials to change the line to different mattress models.
Also it is an extreme advantage to make different mattress size and models on the same time. For this point only a production with several mattress tape edge machine needs to designed. So there is no need to change the mattress tape for different models.
Conclusion: Dark factories for mattress production are not too far away
Now we are discussing how we can eliminate unneccasary moves in the mattress manufacturing with an automated mattress production line.
But the time will come where mattresses will be produced in a dark or lights-out factory.
That means that all steps in the mattress production facility can operate in the dark with zero human intervention onsite. The manufacturing process of mattresses is full of repetitive tasks so it will be possible to implement easily robotics to replace the human intervention.
The dark factory for mattress production can be easily realised for mass production of a single mattress type. But the mattress industry has endless number of product variants and sizes. Because of this reason the vision about a dark factory becomes more difficult.
It is time to automate the factory
To see how you can use automation to improve the manufacturing process a hard decision needs to made by all manager. But journey afterwards optimize every step of production of mattresses.
Mattress production lines will allow you to improve your factory to the highest producivity level and keeping all your production data centralized within your notebook and can be tracked from everywhere.
Now we have discovered some of the benefits of automation in the mattress industry, now it is time to take action.
Interested in automation in your mattress production?
Contact us today!
