No matter what industry you belong to, your main goal is to get the maximum benefit out of your business procedure. Do you agree? The manufacturing industry is one of the main industries that heavily relies on materials and processes and their unification to receive the best at the end of the workflow. However, when it comes to receiving the most out of the materials, resources, and processes you keep putting in, you need to touch on the high notes of the extracting process. Yes, this means the optimal performance of each element! This is where the concept of ‘Yield Optimisation’ has been introduced to the manufacturing realm in the modern world.
In this article, we focus on the prime stage of this entire yield optimisation framework: yield analysis. Last but not least we will look into the benefits of yield analysis for the manufacturing world.
We will understand
What is Yield in Manufacturing?
- Before digging into the deep soil, we need to have a thorough understanding of the concept behind yield optimisation. It goes as follows.
- In manufacturing, ‘yield’ refers to the ratio of usable output to the input during a production process. It quantifies the effectiveness of the manufacturing process by measuring the proportion of acceptable products or components produced compared to the total materials or resources used.
- Yield cannot be decided depending on one aspect. It clearly takes various factors into consideration such as raw material quality, equipment efficiency, and workforce productivity.
- If a manufacturing floor achieves a high yield, this means that it indicates the efficient utilisation of resources and minimal waste during the production process. The obvious result is lower production costs and higher profitability.
- In reverse, If a company achieves a low yield, it suggests that there were some inefficiencies, defects, or process failures that required attention and improvement.
- When a manufacturing company has this knowledge of the high yield and low yield they generate, they can take immediate action and invent new ways to battle these burdens.
What is Yield Analysis?
- In the whole framework of yield optimisation, yield analysis is one stage, yet it is the most vital aspect to proceed with other stages. During the yield analysis stage in manufacturing, manufacturers carefully look at the production data to see how well things are working.
- If put in a simple way, this means they check things like how much raw material they use, how well their machines are working, how many mistakes they make, and how good their final products are. This step is heavily important because it helps manufacturers find where they can do better.
- This is the initial step in fixing problems before they become big issues and helps them make smarter choices to get more out of their production.
- The superlative focus of the whole process of yield analysis is to inspect the production floor elements and whether they are giving out their best for production. When this analysis is done, manufacturers move to the rest smoothly.
Top 4 Benefits of Yield Analysis in Manufacturing
Quality Improvement
If manufacturing is one powerhouse, you can state that it is built on one strong foundation, which is quality. There is no ongoing manufacturing business that compromises quality.
This is where the yield analysis plays a major role in driving overall quality improvement efforts within the manufacturing ecosystem. After thoroughly examining production data, yield analysis helps detect defects and uncover the root causes of quality issues.
This capability empowers manufacturers to pinpoint areas of weakness in the production process, whether it be related to raw materials, equipment performance, or operational procedures. As you can see, if they can address these issues head-on, manufacturers can implement targeted solutions to enhance product quality and minimise the occurrence of defects.
The best thing about this is that it leads to a reduction in the number of defective units produced. In the case of manufacturing, the latter will surely result in higher customer satisfaction and fewer returns. You know that when products meet or exceed customer expectations, it not only strengthens brand reputation but also fosters customer loyalty.
Therefore, yield analysis serves as a valuable tool for manufacturers to continuously improve their processes. Not to mention that it helps uphold quality standards, and delivers superior products to the market.
Cost Reduction
One of the top challenges manufacturers face in production is high costs. Is there any way to defeat this burden? Yes, yield optimisation is the convenient answer in this case. Let us explain how.
During the yield analysis process, manufacturers have all the production data to comprehend yield rates, uncovering areas where inefficiencies lead to the wastage of raw materials, energy, or labour.
When they have a chance to pinpoint these wasteful practices, manufacturers can strategically intervene to minimise or eliminate them in advance. This is how it will help reduce overall production costs.
For instance, if the analysis reveals high scrap rates due to a particular machine malfunction, manufacturers can invest in maintenance or upgrades to enhance equipment performance and reduce material wastage. Similarly, if the analysis identifies inefficient production processes leading to excessive energy consumption, manufacturers can implement energy-saving measures or optimise workflow to avoid these costs.
This is where the beauty of yield lies! When they are powered to optimise processes based on yield analysis findings, manufacturers can enhance efficiency, reduce waste, and lower production costs drastically.
Process Optimisation
If the yield optimisation operations are implemented correctly, manufacturers are able to carefully examine production data to find any problems or slowdowns in the manufacturing process.
This helps them pinpoint areas where things could be done better. For example, if they notice that a certain machine is always breaking down or causing defects, they can focus on fixing or replacing it to keep things running smoothly.
By looking at yield data, they can see where improvements are needed to make the process work more efficiently.
This will drastically change the way things are done on the production floor, upgrading equipment, or training workers to be more effective.
Ultimately, if they can expedite these improvements based on the analysis, manufacturers can optimise their processes to produce more goods in less time, which is the sole objective of the manufacturing industry.
It will undoubtedly lead to increased productivity and better results.
Predictive Maintenance
Maintenance receives a top spot on the list of complex tasks that must be performed by the manufacturers.
During the yield analysis process, manufacturers get the opportunity to keep a close eye on how their equipment is performing.
By looking at a massive volume of production data, they can spot any unusual patterns or signs that a machine might be about to face a potential failure. This helps them predict when maintenance is needed before a problem occurs.
For example, if the operators notice that a machine is running slower than usual or using more energy than normal, it could be a sign that something is about to occur. This will lead to early problem-solving, cost reduction of major maintenance requirements, and unnecessary production disturbances.
Cerexio Yield Optimiser System for Maximum Yield
If you feel like your production floor is slowing down its operations, it is high time to unlock the full potential of your manufacturing operations with Cerexio Production Yield Optimiser System. By deploying the power of Industry 4.0 technology, Cerexio’s solution maximises yield, minimises waste, and visualises your entire production process on one unified screen, all while maintaining a sustainable footprint on the manufacturing landscape.
Enhancing Production Quality through Better Yield Analysis
It is important to enhance the quality of your products while expediting the production cycle. It will be easier if you have a technological solution to battle all your yield-related challenges. However, you are advised to align your industry requirements with the yield optimisation tool you are planning to purchase, as there are many fraudulent products in the market right now.
