A Mass Customization Revolution
A Mass Customization Revolution
The Industrial Revolution
The great social and economic changes due to the introduction of machine and power tools and large-scale industrial production began in 1760. Through the first 70 years of this century, the US was the industrial giant of the world. In 1960 the words “Made in Japan” was thought to be a joke. By 1980, those same words had become the standard for manufacturing. In 1985, U.S. manufacturing was in a deep depression. Products were too costly, of poor quality and not innovative enough.
Now, again, America is ranked No. 1 in manufacturing (World Competitiveness Report, 1996).
Mass customization
America’s No. 1 standing is primarily due to the manufacturing revolution that has been under way since 1985. This quiet revolution is built on the unsurpassed innovative spirit of the American people. Innovation is one of the qualities upon which America is founded. American manufactures are the world’s leading innovators. The right combination of technology and people is a good foundation for any company. These technologies are leading to a major new phenomenon: mass customization, which is the ability to customize products literally in quantities as small as one, while producing them at mass-production speeds. Mass customization in the Information Age is replacing the mass-production model of the Industrial Age.
The ultimate outcome will be simultaneous manufacturing. Here, even as the customer is giving the order, the product starts to be manufactured. It may seem like a fairy tale, but the time is fast approaching when a customer will stand at a retailers fitting room, download their personal measurements into a computer, choose the pattern and variety of material wanted for their clothing and before they leave the outlet their order is in production. Now that’s a truly empowered customer!
Over the past few years, there have been a number of articles written on lasers. Each author lists applications as it relates specifically to their area of expertise. However, what EdgeWISE Tools would like to do in this article is to stimulate you to visualize all the different ways you can use a laser to produce a variety of products. Let your imagination go. Don’t fear the unknown. Those that can see the future have the greatest opportunity to succeed beyond their wildest dreams. “Carpe Diem” - seize the moment!
Why use a Laser?
In 1985, thermal contact cutting tools were developed for roll feed plotters. The “Hot Tip” became the first large format cutting system introduced to the sign industry. This process became the corner stone that most plotter manufactures built on. Through evolution, the cutting hardware has changed and significant strides have been achieved. We have seen progressive steps taken to where technology is today.
Most old manufacturing technology uses contact cutting tools; where the tool actually contacts the surface, it is meant to cut. The cutting tools must be re-sharpened or replace often and as the tool wears out the quality is compromised. This antiquated method has become an additional source of income for the manufactures because they now get to market one or more consumable tools. Contact manufacturing with all its additional costs can now be replaced with a more economical solution.
The next giant evolutionary leap in cutting manufacturing is the replacement of contact cutting tools with non-contact tools. The next logical step is to use laser technology for mass customization. The traditional high cost of laser technology has delayed the development of the Roll Feed Laser (RFL). A day is like a year in technological development terms. However, recently the cost of laser technology has been reduced to the point where today it has become an affordable means of manufacturing.
Roll Feed Laser
In 1988, research and development began on the first Roll Feed Laser system (RFL). This research developed more than just a new product. It developed new concepts in manufacturing and new ways to manufacture. The realization of mass customization is appearing using lasers. The combination of these two things EdgeWISE Tools calls the laser manufacturing revolution. This laser manufacturing revolution we are beginning to see is becoming bigger than anyone has yet imaged. There are literally hundreds’, if not thousands’, of markets and industries that have yet to be discovered.
Can you change?
As history has proven, there are always those people that lack the foresight and intuition to respond to the changing trends of time. Ten years ago, in 1986, industry scoffed at the idea of a large format, computerized, cutting system becoming the main work tool for the trade. The resistance to change at that time was severe. Seven years ago most plotter manufactures laughed at the idea of a low wattage Roll Feed Laser system and could not see the potential for manufacturing one. Look at what is happening today, Since 1990, the number and diversity of applications for low wattage CO2, Nd:YAG and Diode laser systems have exploded. The CO2 laser market has grown on average of 60% per year. More people are recognizing the benefits of using a CO2 laser over other traditional manufacturing tools. Machinery like dies, routers, hot knives, and mechanical engravers are being replaced with affordable low wattage RFL systems. Ink jet printers, in some applications, are losing ground to the advancing low wattage laser used for marking.
What does this mean?
In what other business can you invest in a piece of equipment to produce such a variety of different products? Products can be manufactured using plastic, woods, fabrics, rubber, and metals. Because the kerf is very narrow and the laser controlled by a computer nearly any design can be cut. It is just as easy to cut one design as it is to cut a million. Comparing this too most manufacturing equipment, you could invest $50K to $500K on an offset printing press. However, you can only use this equipment to print on a specific type of material. A silkscreener, sign maker, engraver, or for that matter most everyone in the manufacturing field, will purchase a specific piece of manufacturing equipment to accomplish a specific task. A machinist may be one of the only people that will purchase a piece of equipment and be able to work a small number of different materials. The machinists’ limitations show up in the restricted types of designs he can shape. Nevertheless, even a machinist’s tools cannot work with the variety of materials and designs that one can attain using a Roll Feed Laser.
Acquiring capital equipment is usually difficult for a new or growing business. Capital investment is one of the major issues for a new or growing business. To a start-up company, or a company that is seeking to reinvest, capital investment is the one main issue that is becoming harder to justify. A piece of capital equipment that is designed for just one purpose is not cost effective when a multifunctional alternative is available. The capital investment to produce an exclusive product has become such an immense cost that these moneys are rapidly shrinking. Switching to the use of a laser for manufacturing is a contemporary new process. A process that, if not adhered to, could cost the business owner market share, and ultimately his market completely. Most of us have known someone that this has happened to in the past. Reluctance to change can cause the demise of any very good company. EdgeWISE Tools is unaware of any other process that can produce the variety of products and open up design creativity as much as what you get when you use the RFL. Nowhere else can you work with paper to plastic to wood and pretty much everything in-between and back again with one piece of equipment. The only challenge now is left up to the ingenuity of the owner or operator to produce the product.
Since a laser does not come in contact with or use force on the material being manufactured spoilage can be drastically reduced. Lasers will increase a companies yield. Some surveys show a yield rate of 95% to 99%. Having owned a graphic arts manufacturing facility in the late 1980’s, on the best of days the yield was 80% to 85% and on average the yield rate would be 75% to 80%. The lack of contact with materials attributes to the higher yield rates. Because the process of using a laser is automated, the process tends to be far more repeatable than most methods. Once the process starts, it is frozen and day to day repeatability is maintained.
The future is at hand!
Imagine the industrial revolution…now imagine the industrial revolution with mass customization. A comparable example mass-customization is the jeans industry. Only the affluent could afford to purchase a pair of custom-made jeans from a tailor. Most consumers can only buy jeans in sizes manufactured to suit the cost of production, not body shapes. As mass-customization technology is available, manufacturers need to again provide the American people with a quality product. The jeans and roll feed laser industries are forerunners in the race to make mass-customized products accessible to consumers
The industrial revolution made products affordable by mass-production. This mass-production required only one setup to produce thousands of pieces. The cost for tooling is one of the largest expenses, which controls the break-even-point. During the industrial revolution, customization was compromised to maintain low manufacturing costs. Today, however, you have the opportunity to choose to take the next step to processing power, user-friendly software, low wattage laser technology, and minimal to no setup time. As you contemplate capital investments, consider end-product quality, cost-effectiveness, and efficiency of roll feed laser technology.
Written in 1996 by:
Patrick J. Momany, Founder of EdgeWISE Tools, Inc. www.ewt-inc.com
Edited by:
Marty Kalberer, Laser Systems Engineer.
EdgeWISE Tools founder Pat Momany — didn’t start out at the high-tech edge of the fabric cutting industry. Problems that need solving get his inventive juices flowing, and his penchant for saying, “Sure, we can do that,” before figuring out how, add up to an enterprise that’s reinvented itself several times. Now with that trademark inventiveness and can-do attitude, Seattle-based EdgeWISE is pushing the limits of fabric cutting, in a system custom-designed to cut out the huge scientific balloons NASA plans to send to the very edge of Earth’s atmosphere.
Previous Articles Highlighter:
Why PR Is An Engine For Economic Growth (1)
In that way, those same business, non-profit and association managers can see results such as new proposals for strategic alliances and joint ventures; customers making repeat purchases; prospects starting to work with them; membership applications on the rise; capital givers or specifying sources looking their way, and even bounces in showroom visits.
Step Back To Succeed In Decision Making (2)
Whether they realise it or not, they are operating in a fashion that mimics most (if not all) of the greatest leaders of our time. This trait can be learnt, but for some people it is easier to master than others.
How To Negotiate A Settlement With An Insurance Claims Adjuster By Dan Baldyga (3)
You be the listener. Let him babble on. When he's finally done, you say, "Your points about my injuries are very interesting. I'd like to discuss them in detail with my doctor“.
Something New For Managers (4)
Then move them to take actions that lead to your success as a manager working for a business, non-profit or association. Here’s one way to do it. Decide that you’re going to spend some quality time with your PR folks and tell them you really want to find out what those outside audiences, those with the behaviors that really impact your operation, actually think about you.
7 Work At Home Mistakes To Avoid (5)
Look at it this way , say you sign up someone under you , and they need help getting started , how are you going to help them if you do not even know this?
Three Proven Steps To Improve Your Home Business Advertising Response In Just 1 (6)
Since the offer is subject to your terms, you set a date when the offer expires, a number they have to call, a letter that they must bring in, a form that they must fill out.
This Is The Power Of PR (7)
Using many of the same questions used in the first benchmark session, you’ll now be alert for signs that the bad news perception is being altered in your direction. Should things slow down, you can always accelerate matters by using more communications tactics along with increased frequencies.
Working As A Knowledge Worker In The Information Age (8)
The same technology which has enabled this to happen, has also reduced the time between communications from weeks to seconds. There is simply no officially available time within which to conduct the communications on which networking and interpersonal contacts depend.
Networking 1 (9)
Networking is not a one-way street.Many times by having contacts in companies you want to do business with, you can find out how they want proposals, bids or contracts done beforehand, and gear your paperwork towards this end.The library is a good source, so are the publications you subscribe to.
The 6 Stages Of Modern Career Development (10)
Key characteristics: Providing first-class customer service skills Building a professional networkThe Transition Stage is characterized by feelings of discomfort, in that you are unsure of what you will be doing next (and/or if you will be happy).
Ten Effective Ways To Reduce Your Business Costs (11)
You could get a membership at a wholesale warehouse or buy them through a mail order wholesaler. Buy the supplies you are always running out of.4. Free Stuff You should try visiting the thousands of freebie sites on the internet before buying your business supplies.
Achieve More In 2 (12)
Remember to set a deadline. A goal without a deadline is simply a dream. Attach a realistic yet challenging deadline for accomplishment and post this where you can review it regularly.Phrase your goal in the present tense and assume success.
Time Out (13)
Our family benefits from the presence of our children's great grandmother, who begins her 91st year, likes football ("Oh, that poor Drew Bledsoe."), but dislikes current interest rates. Clearly, her perspective includes long-term opinions on history, mores, and the economy.
Common Mistakes Motorcycle Buyers Make When Looking For A Motorcycle Loan By Jay Fran (14)
(Simple interest is always better because it does not penalize the motorcycle buyer if the loan is paid off early.) What is the down payment requirement to get the motorcycle loan?
Surviving The Workday In Your Organization (15)
All of these factors have an impact on the bottom-line, a good enough reason for your organisation to invest in helping you and your team learn the skills to be as effective as possible.Lorraine Pirihi is Australia's Personal Productivity Specialist and Leading Life Coach.
The Delicate Art Of Balancing The Budget (16)
The existence of a mechanism to amend budgets is, therefore, of the essence and to be greeted. A budget amendment is often ceased upon by the opposition as proof of the government's fallibility and failure.
Team Effort Pays Off For Entrepreneurs (17)
Copyright 2003 Permission required before reproducing.Mike Menaker is a certified business coach with Action International- New Jersey. He draws upon more than 25 years of business experience to help small and medium-sized companies to become more successful.
Making The Dealer An Offer By Kevin Schappell (18)
Make sure you mention this to the salesman; it's a good bargaining chip. What next? Wait......... if they do not take the deal, politely leave your name and phone number and go home.
Classified Ads What Works What Doesnt (19)
Do classified ads really work? Should you include an email address or fax number in them? How about a call to action? Questions like these are often brought to the attention of OhioHelp.net, an Ohio-based company specializing in helping businesses worldwide with their marketing, public relations and freelance writing services.
Choosing The Best Life Insurance Option For You (20)
SummaryBoth level term insurance policies and whole life policies offer valuable peace of mind to policyholders. The cost of this type of life cover is a small price to pay for the peace of mind that comes with being protected, and you can increase this peace of mind by adding extras such as critical illness to your policy for just a small extra fee.As a nation, we like to insure just about everything we can...our cars, our homes, our belongings, our pets, and even our credit repayments.
Newer Articles Highlighter:
Better Decisions Balancing Efficiency BuyIn (1)
Communicate this clearly. 2. Who else will participate or have input? You may own a decision, but if you dont have all the relevant expertise or information, you may want to include other people.
Why Mobile SMSText Messaging (2)
However, though they have complete control over network infrastructure, they are generally not too keen to service customer for meeting their messaging needs. The prime reasons for this are: Enterprise messaging involves complex integration with backend database/applications The volume of messages is typically not high (except in large B2C companies) The criticality of message delivery is extremely high Operators largely cross subsidise ‘voice’ with ‘data’ services. It a specific network is down, then the service suffers.
Why Your Mutual Fund Doesn’t Return As Much As You Think (3)
the S&P 500's 9.1% drop, investors in the average fund actually lost around 3% when you add in the fees and capital gains taxes they must pay, says James O'Shaughnessy, CEO of Netfolio.com and author of the bestseller What Works on Wall Street."Mutual fund performance figures often leave out the taxes and some fees you are required to pay as an investor," says O'Shaughnessy, a former mutual fund manager and architect of a new investment service that eliminates the big drawbacks of mutual funds.
Useful Tips On Buying A New Or Used Car By John Mussi (4)
The loan can be used for any purpose, and is available to anyone who owns their home. Home loans can be used for any purpose such as, new car, home improvements, pay of store card or credit card debt and debt consolidation.
Venture Leasing A Smarter Way To Build Enterprise Value (5)
Correcting this situation can sap the entrepreneurs’ time and energy.How Venture Leasing WorksGenerally, a major round of equity capital raised from credible investors or venture capitalists makes venture leasing viable for the early stage company.
Using Sector Funds To Construct Diversified Mutual Fund Portfolios (6)
The information contained in this report is obtained from various sources believed to be accurate and is provided without warranties of any kind. AlphaProfit Investments, LLC does not represent that this information, including any third party information, is accurate or complete and it should not be relied upon as such.
What Is Road Hazard Warranty? Do You Really Need It? By Gene Grant (7)
Let's say your tire is 1/2 way worn at the time of the flat. With tires averaging $100 each, your replacement cost would only be $50.00. Much better than full price, yes?
To Grow Out Of Unemployment (8)
New professions, connected to new technologies, emerge. Some workers can be retrained but even this takes time (in which they might, technically, be defined as unemployed). Others cannot be retrained and they join the ranks of the long term unemployed, swelling structural unemployment.
How To Take Your Stalled Projects To The Finish Line (9)
Instead, say, "I don’t feel ready to move in that direction. I’ll write down the idea and file it away for the future."(2) Tell a story about what would happen if you finished each project.
Temp Gretta And The Great Seattle Race (10)
A size 22 boot slammed on the gas and his big shiny machine shot through the darkness -- through the parking lot and clean through the chain link fence.His tires squealed, his engine roared and the strained metal of his rig cried out in anguish as he desperately tried to make the turn.
The Rules Of The Road By Kevin Schappell (11)
While not taught in most driver education classes or state driver's manuals, these rules will help you be a better driver. The left lane is for passing. If you are going to pass, do it quickly and safely.
Social Engineering The Real ETerrorism (12)
Implement a formal incident reporting mechanism for all security related incidents to ensure there is a rapid response to any breaches. Ensure that the company has security policies and procedures in place, that all staff are aware of them and that they are followed.
Who Is Running Your Business (13)
It may come from the question "Who is running your business?" Would the vendor have better maintained the customer if he were a little less available?This article is special, as it addresses the entrepreneur: those of us in business who have chosen to leave Corporate America behind for the good life.
Can You Really Improve Your Organisation Skills (14)
But first I have to "want" to learn that skill. I have to see the need and the resultant advantage to me and my business and then I will be willing to learn a new skill.""Orderliness is a character trait.
Want To Loosen Uncle Sam’s Grip On Your Wallet (15)
Capital losses can be used to offset capital gains, dollar for dollar. In addition, you may use up to $3,000 of losses to reduce your ordinary income. If you have losses exceeding $3,000, you can carry them forward and apply them to next year's taxes.Be Smart about Higher Education CostsThe Taxpayer Relief Act of 1997 created a number of tax-advantaged ways to pay for college.
Why Choose A Bad Credit Personal Loan (16)
However created, your past record of CCJ’s (County Court Judgements), mortgage or other loan arrears can live on to deny you access to finance that other people regard as normal.
The 21st Century Way To Build Equity (17)
On a biweekly mortgage payment schedule, one half of a loan's monthly payment is made and credited to the account holder every two weeks. This is equivalent to making 13 monthly payments instead of the usual 12 monthly payments reducing the loan's payoff time.3.
How Your Auto Insurance Rates Are Determined By A. Chris Tijerina (18)
Even if you live in a affulent area your rates may be higher due to the higher value vehicles in your area cost more to fix than in an area with lower value vehicles.
Characteristics Of High Performance Teams (19)
Traut is the president of Entelechy, Inc., a company that helps organizations unlock the potential of their people through customized training programs in the areas of sales, management, customer service, and training.
What You Must Know When Marketing Your Business (20)
What kind of image do you want to project? What are the benefits of doing business with you?COMPETITIVE ANALYSIS Purpose and function of your product or service What makes your business unique from other similar businesses?