Precision machine shops across the country strive to set themselves apart from competitors by enhancing their offerings to cater to specific customer needs. These offerings often include value-added services such as welding, painting, heat treating, and more. Additionally, machine shops may specialize in accommodating different batch quantities, product sizes, specialty materials, and other unique requirements. One particularly significant value-added service that some machine shops undertake is contract assembly and system integration. This service involves assembling components into finished products or integrating various systems into a cohesive unit. While it can be a complex undertaking, providing contract assembly and system integration sets machine shops apart by offering a comprehensive solution to customers’ manufacturing needs.
The Misconception of Assembly and System Integration Services
While some precision machine shops have started to dabble in assembly and system integration services at a low level for some simpler products, establishing a legitimate business unit dedicated to this requires a high-level approach and substantial resources. The time, effort, and financial investment involved are considerable, encompassing equipment, software, real estate, and skilled personnel.
What to Look for in a Sophisticated Assembly and System Integration Provider
Slow and organic growth is a prudent approach to incorporating this offering into a precision machine shop’s business model; however, OEMs should exercise caution when selecting a vendor for their assembly and system integration requirements. It’s essential to ensure that the chosen partner has the expertise, capacity, and commitment to deliver the quality and reliability expected in this complex and critical aspect of manufacturing.
1. Customized Assembly Work Cells
Great machine shops with sophisticated assembly and integration services require substantial space to set up manufacturing work cells effectively. These spaces can range anywhere from 3,000 square feet to over a million. Based on experience, shops in this category typically fall within the 100,000 to 300,000 square foot range. To be considered a high-level turnkey assembly company, this amount of space is likely essential, along with adequate lighting, fixtures, ventilation, and other necessary tools for assembling jobs accurately. The size and layout of the shop play a significant role in the efficiency and effectiveness of the assembly processes carried out within it.
2. Time and Experience
Time and experience play crucial roles in achieving success in assembly and systems integration. Just like precision machining, assembly requires a blend of art and science to ensure optimal outcomes. It involves managing labor, parts, quality systems, and processes, which can be quite challenging. Therefore, having skilled employees in appropriate roles is essential for efficiency and profitability. A team comprising skilled manufacturing and process engineers is integral to the success of any assembly project. But even with all the space, tools, and software out there, building the right team does not happen overnight. It demands meticulous planning and thorough consideration. Unfortunately, many precision machine shops struggle with this aspect, leading to a scarcity of teams capable of producing high-level assemblies. Without a cohesive and proficient team in place, even the best resources and technology may fall short in achieving desired outcomes in assembly projects.
3. Intelligent Manufacturing Software
Maintaining an accurate and intelligent manufacturing software system, such as ERP or MRP, is absolutely critical when managing the myriad parts needed for assembly and system integration. Unlike the straightforward management of materials and scheduling for CNC machines, handling assembly and integration demands a sophisticated and agile system to orchestrate the seamless flow of numerous components onto the assembly line at precisely the right moment and pace. Mastering this coordination is where MRP systems excel, but exceptional contract manufacturers have honed and customized these systems over time to align perfectly with their own operational requirements as well as the specific needs of their clientele.
The reality is that most precision machine shops simply lack the capability to provide the assembly and integration services required for high-level assembly overnight. This process is not something that can be rushed or achieved without proper planning, resources, and expertise. It demands a significant investment in terms of commitment, capital, and leadership. Only through years of meticulous planning and gradual expansion can assembly and integration companies develop the necessary infrastructure and talent to succeed in this complex business.
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