Automation is revolutionizing industries across the board, and body armor manufacturers are no exception. Through automation, body armor companies can increase production capacity, reduce error rates, and improve product quality while lowering operational costs. Yet, successfully adopting automation is more complex than buying and implementing the latest technology. It requires a careful and systematic approach.  

10 Critical Aspects Body Armor Companies Need to Consider for Successful Automation in Their Manufacturing Processes

1. Strategy Development

   A clear and well-defined strategy is the cornerstone of successful automation. Body armor companies should analyze their business goals, current challenges, and automation potential. This will help decide what areas would benefit the most from automation and formulate a strategic plan to guide the automation journey. 

2. Employee Involvement

   People are a vital part of any manufacturing process, even one that's automated. Ensuring employee involvement and buy-in from the beginning is crucial. Training programs must be implemented to familiarize employees with the innovative technology and upskill them. Also, fostering a culture that values innovation and change can help reduce resistance to new systems. 

3. Selecting the Right Technology

   Many automation technologies are available today, and not all will suit every company's needs. Careful assessment of the different capability, scalability, and cost-effectiveness options is needed to select the technology that will best meet the company's goals. 

4. Process Standardization

   Manufacturing processes must be standardized and documented before automation can be implemented. This ensures consistency and predictability, which are essential for effective automation. It also makes it easier to find inefficiencies that can be addressed through automation. 

5. Quality Assurance

   The automation system should include stringent quality control measures to ensure the production of high-quality body armor. Automated quality inspection can reduce human error, ensuring that every product meets the established standards. 

6. Product Design for Automation

   The body armor design should be conducive to automation. This might mean redesigning some aspects of the product to allow for easier assembly or machine inspection. Digital design tools like CAD and simulation software can be beneficial in this process. 

7. Data Analytics

   Automation systems generate a vast amount of data. This data can supply valuable insights into the production process if used correctly. Analytics can help show inefficiencies, predict maintenance needs, and guide decision-making. 

8. Safety Considerations

   Safety should be a primary concern in the automation of manufacturing processes. This includes not only the safety of the workers interacting with the automated machinery but also ensuring that the automated process produces body armor that is safe and reliable for the end users. 

9. Maintenance and Support

   Automated systems require regular maintenance to ensure their ongoing effectiveness. A robust maintenance program and prompt support will help maximize uptime and productivity when issues arise. 

10. Continuous Improvement

    Successful automation is more than a one-and-done process. It requires ongoing monitoring, evaluation, and improvement. Advances in technology should be continuously assessed for their potential benefits, and feedback from employees, customers, and the automated systems themselves should be used to refine and improve the automation strategy. 

11. Bonus Tip: The ROI (return on investment)

    Conduct a thorough Return on Investment Analysis - It's essential to remember that automation should enhance your manufacturing process, not hinder it. A comprehensive return on investment (ROI) analysis is non-negotiable. This analysis will ensure your automation efforts don't inadvertently compromise output quantity, quality, or cost. Remember, the goal of automation is to improve efficiency and productivity, so any operation that suffers in these areas post-automation might not have been analyzed correctly. Always ensure that the benefits of automation outweigh the costs and potential risks. 

People

The power of automation is fully realized when your workforce is fully engaged and equipped. Business development teams that excel by using automation technology lead the way in strategic bid management, contract award, compliance, and modifications. Data analytics, a key asset in the era of automation, is crucial for informed decision-making, competitive intelligence, and competitor analysis. This data-informed strategy empowers your team and refines your manufacturing processes for ballistic-resistant products, marketing strategy, and overall financial performance. 

Product

Automation in manufacturing helps engineer NIJ-certified and compliant body armor, contributing to enhanced quality control. This ensures regulatory compliance, including ITAR, FAR, and DFAR compliance, and directly affects customer satisfaction and retention. By closely considering customer behavior, your products can be designed and developed to meet emerging market trends, leading to successful product launches and best product positioning. 

Process

Process automation is a strategic tool for creating a resilient global supply chain, an absolute necessity for defense contractors. It aids in sourcing materials and components, managing subcontractors, and enabling effective resource allocation. Automation also aids in risk management in the supply chain, contributing to a robust continuous improvement program. Companies can gain a competitive edge by using automation in proposal development and contract negotiation and focusing on an effective pricing strategy. 

In this increasingly competitive environment, integrating automation into manufacturing processes is no longer a luxury; it's a necessity for body armor companies. Success lies in strategically applying automation to people, products, and processes. In doing so, businesses can ensure they are still at the forefront of innovation in armor, meeting the highest standards of safety and protection and delivering improved customer satisfaction. 

Case Study: Automated Sheeting Transforms Body Armor Production    

For body armor manufacturers, efficiency and precision are of the utmost importance. This is precisely why adopting an automated sheeting machine to cut technical fabrics can be a game-changer.  

Let's dive into an example of how automation can streamline manufacturing and deliver a substantial return on investment (ROI).  

The existing manual process involves two laborers who take roughly 45 seconds to 1 minute per layer. Each laborer works an 8-hour day with two paid breaks, with a total labor cost of $30-40 per hour per person.  

Enter the automated sheeting machine. Priced at $75,000, the machine requires only one person to operate intermittently, spending approximately 15 minutes per hour. This machine can lay and cut one layer per minute, matching the speed of manual labor. However, the machine's standout feature is its ability to count layers automatically, significantly reducing the risk of human error.  

The financial implications of this automation are noteworthy. Annual labor costs per laborer can reach $62,400, assuming an hourly cost of $30 per man-hour. Meanwhile, the automated machine incurs a yearly maintenance cost of $1,200, and the labor cost for machine operation is roughly $3,900 annually.  

When calculating the total annual cost of automation ($79,100), we find that the yearly savings due to automation amount to around $45,700. Additionally, we see an estimated $6,240 in savings due to reduced errors in layer counting. This sums up to total yearly savings of approximately $51,940. 

As a result, the ROI on the automated sheeting machine is about 69.2%, factoring in the additional savings from reducing layer count errors and the increased productivity from having cutting machines run for the entire shift. 

In this simple example of many available, transitioning to an automated sheeting process isn't just viable; it's financially beneficial. This technology investment pays for itself and contributes to a significant increase in production efficiency. With such a substantial ROI, it's clear that automation is the way forward for body armor manufacturers seeking to enhance their manufacturing process. 

Here are 5 Valuable Resources for Educational & Improvement Purposes 

1. MIT OpenCourseWare

   Introduction to Automation: This course supplies a comprehensive introduction to automation. It covers assorted topics, including the principles of automation systems, their analysis, and their design. The course materials are available for free here.  

2. The Association for Advancing Automation (A3)

   A3 supplies various automation resources, including webinars, reports, and articles. You can find their resources here. 

3. SME (Society of Manufacturing Engineers)

   This organization offers information about manufacturing technologies, including automation. They offer webinars, events, and many articles that can be accessed here.

4. Automation World

   Automation World is a digital magazine dedicated to the latest news and technologies in automation. It is an excellent resource for keeping up to date with trends and advancements in manufacturing automation. Visit their website here.

5. edX - Principles of Manufacturing MicroMasters Program by MITx

   This MicroMasters program helps you to learn the principles of manufacturing: process control, production flow, supply chain, and finance. The foundational skills taught in this course will be invaluable as you consider how automation affects all aspects of manufacturing. You can access the course here. 

Remember, while learning from these resources, the practical application and the specific needs of your organization are paramount. Tailoring the insights you gain from these resources to your unique context will be crucial for successful automation. 

To make your journey toward automation seamless and efficient, we at IntelAlytic stand ready to help you. Our ability and dedication ensure that you successfully harness the power of automation, gain a competitive advantage, and enhance your overall operational effectiveness. Do not hesitate to contact us today and start your journey toward manufacturing excellence. 

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