Why Automation in Mattress Production?
The word "automation" is a broad term that conjures up a different image
for different people. Thanks to futuristic tales of science fiction 50 years
ago, many still think it means the total conquest of the manufacturing
factory by full-scale robots. In truth, there are many degrees of
automation and most are much more attainable than you imagine. In the
purest form of the word, automation does imply using mechanical means
to replace or reduce your reliance on human activity to perform a task.
Your “automatic” garage door opener is a popular example of
automation, and that’s not so intimidating, is it?
Let’s look at the manual steps this simple automation has replaced:
Temporarily Park the car
Get out (possibly in the rain) and walk to the garage door
Raise the garage door
Return to the parked car
Drive the car into the garage
Get out the car and return to the garage door
Pull the door closed
Like your garage door opening activity, we need to identify repetitive
human activity in your factory and see what can be replaced with
automation. Be sure to analyze the sub-tasks involved with the process to
make sure nothing is taken for granted. Notice that in the garage door
example, only steps three and five add any value to the process. The
other five steps are non-value-add activities that offer no benefit to the
As far as our mattress industry is concerned, the bed-in-a-box is an
example of how automation has changed the mattress industry. Our ARP20 Model is capable of Automatically wrap, compress and roll the
mattress which is simply removing the human work of putting the mattress
in a plastic bag and then bringing the mattress to a compressor and then
rolling it by hand. We have secondary roll pack options available with
Atlanta Attachment which does secondary rolling to make the length of
rolled mattress to half. So in a truck where you can put only 110 mattresses
can be filled with .510 mattresses, basically 5times more!
WHAT MAKES AUTOMATION?
- Optimize Labor
- Inventory Reduction
- Productivity Increase
- Deskilling Operator
- Multi-tasking Equipment
- Material Handling
Workforce optimization is the biggest goal of automation. Efficiency still
greatly depends on the employees operating the machines and making
their way around the factory floor. To increase labor efficiency, it's crucial
to place workers in the right place at the right time with the right
resources. One of the big segments of resources is machines. For example,
our K-25 semi-automatic mattress tape edge machine, the worker needs
to sew, move around the table, flip it with hands, etc. Producing 90 to 100
mattresses in a shift Now if we replace this machine with K-40 Fully
automatic model, the worker needs to just focus on sewing which
improves the efficiency of labor as he is producing more mattresses in
much lesser time. We can produce around 160 to 240 mattresses in 8
hours depending on different sizes.
Reducing and optimizing labor leads to a reduction in inventory. For
example, every operator needs at least 3 pieces. 1 piece in the process, 1
piece waiting to be processed, and one piece after the process. means if
you reduce this operator, you have at least 3 pieces less in the process. In
our factories, we use bundles, which means at least 20 pieces’ lees per
operator. So a machine covering 4 operations reduce 4 operators which
means around 60 mattresses less. hence a great reduction in inventory. In
the picture, you can see the units are laying on conveyors because you
only can add a particular amount of mattresses that can fit a conveyor
which means one piece of conveyor can just have one mattress, not a
bundle of mattresses lying.
Automatic machines increase the speed of the process leading to great
output capacity. An example of the same is our Full Border solution
machine 3261P from Atlanta Attachment USA. A single unit is doing
automatic serging or overlock of both the sides of the border, measure, marking label cutting, and losing it. We can make 100 to 120 finished
borders in just 1 hour.
If it's not possible to replace the labor with full automation, simply making
the task easier and safer for the employee is a beneficial step. The 4300BN
Automatic Vertical Handle machine is a good example of the same. A
worker just needs to press a button and the machine will do automatic
overlocking, measuring, attaching vertical handles, and cutting.
Automatic Vertical Handle Machine Dual Overlock Module
Multi-tasking equipment improves productivity exponentially
Machinery makers like UMIT Makina and Atlanta Attachment have
identified many ways to combine process steps to fewer machines can
perform all the tasks required to create the product.
This type of machinery typically performs repetitive tasks that are easily
computer-driven like measuring, cutting to size, electronic sensorcontrolled sewing, and much more. Most can store hundreds of
programmed dimensions in the computer's storage for batch processing.
Our TH-40 Automatic Mattress Gluig line is one of the best examples of it has endless mattress production recipes of gluing applicable from multilayer to single, Bonnell to pocket even Allows Hybrid mattress production
HCA with Atlanta Attachment and UMIT Makina are capable to automize
any mattress factory across the globe.
Umit Makine is an equipment supplier based in Istanbul, Turkey has been
supplying machinery to the furniture and mattress industries for more than
three decades. It exports to more than 100 countries.
The brand Umit Makina has become one of the most known and reliable
firms among mattress machinery manufacturers. Umit Makina's strategy
towards the customers and manufacturing processes helped a lot to
match the brand name to trust, high quality, and innovation.
Umit Makina has managed to export 95% of its production to numerous
countries. They have more than three thousand machineries operating in
the mattress production industry throughout the world.
HCA is being associated with Atlanta Attachment for years. Their mattress
manufacturing machines are considered to be one of the highest quality
materials and workmanship. They utilize heavy-duty industrial sewing
machines for building their workstations. Founded in 1969 as an innovator
of custom-made sewing machine attachments, folders, hemmers, binders,
and other labor-saving devices for apparel sewing equipment. AAC is
now one of the industry leaders in developing sewing automation for
mattress production. Their technology solutions extend to mattress
packaging equipment, quilting machines, decorative border workstations,
and other mattress manufacturing machinery.
HCA with UMIT MAKINA and ATLANTA ATTACHMENT has one aim to reach
every mattress maker and help them in their journey to make their
mattress-making facilities automated and affordable with our 24 x 7
service and after-sales support.