Although lean manufacturing as a concept of production has been around for decades — it originates from post-World War 2 Japan — it wouldn’t take off as the lean we know now until the 1990s and early 2000s as companies scrambled to learn from Toyota’s lean manufacturing practices.
Lean manufacturing methods centre on streamlining operations, minimising waste, and delivering consistent product quality. A crucial but often overlooked element that plays a role in these objectives is moisture measurement. Ensuring accurate moisture content across materials and processes can substantially impact the overall efficiency and quality of production.
What Is Moisture Measurement?
Moisture measurement is a process for determining the amount of moisture, or water content, present in a substance or material. In manufacturing, moisture affects processes in two ways:
- Moisture can be an essential component of a produced material
- Moisture can be an integral factor in a manufacturing process.
Moisture control methods in manufacturing range from drying processes (e.g., oven drying) and adding chemicals (e.g., dessicants) to more precise methods such as using Near Infrared (NIR) technology. Each method has its pros and cons, but ultimately, your choice of moisture measurement will depend on factors such as:
- The type of material being measured
- The required accuracy
- The moisture range of interest.
Moisture measurement plays a vital role in controlling manufacturing costs across various industries, from construction and agriculture to food processing, pharmaceuticals, and biomass materials.
The Importance of Accurate Moisture Measurement in Lean Manufacturing Methods
The precise control and measurement of moisture in manufacturing workflows support the core elements of lean manufacturing.
5 Steps of Lean Implementation
Below is a closer look at how moisture measurement and lean manufacturing methods come together.
- Moisture measurement reduces wastage — a key component of mapping the value stream. Having the correct amount of moisture involved in manufacturing means a streamlined and cost-efficient process that avoids excessive waste.
- Moisture measurement also supports the process of seeking perfection, allowing manufacturers to create finished goods with consistently high quality. Fluctuations in moisture levels can result in inferior products, equipment malfunctions, and increased costs.
- Moisture measurement enables the creation of a pull-based system where materials and smooth production runs support just-in-time delivery.
Related Reading: Unlocking Precision with IR Technology and Non-contact Temperature Measurement — Metals Industry
The 5 Ways Moisture Measurement Supports Lean Manufacturing Methods
1. Optimising Raw Material Usage
Raw materials are the first touchpoint in almost any manufacturing process. The moisture content of any raw material, whether it’s food byproducts, wood or paper, can dictate the final product’s quality, shelf life, and usability.
For instance, maintaining correct moisture levels in clay (the raw material) is critical in producing house bricks (the finished product).
- Too much moisture means longer drying cycles during manufacturing, which, in turn, slows down production. When this happens consistently, the manufacturing process becomes more expensive (due to slower, longer lead times) and higher energy costs.
- Conversely, too little moisture in clay leads to a weak brick that ends up being rejected. Without proper moisture measurement, weak bricks could threaten the structural integrity of a building.
2. Preventing Production Delays and Reworks
Moisture measurement is also critical in food production. Consider a crisp manufacturer, for example. Moisture content determines the perfect crisp — crispy and crunchy but not overly brittle.
A crisp with too much moisture becomes soggy and prone to spoiling too soon. Too little moisture, and the crisp breaks apart too easily. Proper moisture control also ensures the crisp has the optimal absorption level, ensuring even flavour distribution and an optimal shelf life.
Related Reading: Crisp Secrets Revealed! Locking in Freshness and Analysing Oil and Moisture Content
The average large-scale snack food manufacturer can produce thousands of kilograms of crisps per hour. If, during production, the moisture level has changed even just slightly and isn’t immediately detected, huge volumes of crisps would be wasted, and the production line halted while the levels are rectified. The result is costly wastage and production downtime.
Get the Nordson Series 9 Food Moisture Gauge at Control Metrix
This scenario is precisely why many large-scale manufacturers use online measuring equipment like the Nordson Series 9, which uses highly accurate NIR technology to constantly monitor moisture levels in food-grade materials and alert production teams to any issue. This tool allows food manufacturing companies to reduce wastage and downtime
3. Enhancing Equipment Efficiency and Longevity
Improper moisture content also affects the condition and longevity of manufacturing equipment, increasing the risk of equipment failure.
Manufacturing machinery is set up to handle materials with specific properties, including moisture content. When materials with incorrect moisture levels are processed, it can result in poor material flow, malfunctions and even breakdowns.
Let’s go back to our brick manufacturer example. Processing clay that’s too wet can damage equipment. Because bricks are fired in kilns at very high temperatures, using clay with high moisture content can cause rapid buildup in steam pressure — increasing the risk of explosive spalling or cracking.
When this happens, manufacturers have to bear the cost of repairing equipment and have to factor in downtime while waiting for repairs or replacement equipment.
4. Ensuring Product Quality and Consistency
The end goal of any manufacturing process is a high-quality product. In sectors such as the food process industry, even a slight deviation in moisture content can negatively alter product quality, shelf life and the impression the product makes on consumers. These qualities in a food product will determine whether a food company can meet customer expectations.
Let’s say you want to purchase a packet of chocolate digestives from a well-known brand you like. You’ve had them several times, and you like how they taste.
But what if, in your next purchase, the first bite into the biscuit is too crumbly and dry, forcing you to reach for a glass of water? Or what if the biscuit feels greasy and soft? In both cases, your expectations have not been met.
Now, think of that experience and scale it to thousands of customers. That poor product experience can damage a brand’s reputation, leading to lost revenue and additional spending to restore brand equity.
5. Reducing Energy and Resource Wastage
It’s no secret that the manufacturing sector is one of the world’s leading contributors to climate change. In 2019, the UK food system was estimated to account for approximately 35% of the country’s territorial carbon emissions. Simply put, food and beverage manufacturers and the overall manufacturing sector have a moral imperative to streamline their processes to help the UK meet its Net Zero goals.
Water and energy usage are the obvious starting points in manufacturing efficiency, so investment in technologies to control moisture levels consistently is an easy win. For example, moisture control also affects energy consumption — think of the energy a kiln uses to dry wet brick. In a facility with production lines running 24 hours a day, controlling moisture to prevent delays and longer workflows can significantly reduce energy usage.
With energy costs a hot topic in recent months, every little thing manufacturers can do to reduce their energy costs can directly affect their bottom line.
Moisture Management: A Critical Detail in Lean Manufacturing
In the realm of lean manufacturing, the devil is in the details. Moisture measurement, though subtle, can have a profound effect on manufacturing processes, whether these involve bricks, crisps or biscuits. By investing in technologies that accurately and efficiently monitor moisture levels, manufacturers can enhance their products’ quality, production efficiency, and overall profitability.
Follow the Control Metrix Blog to find more insights into the world of non-contact measurement in industrial settings. If you need the latest NIR moisture measurement solutions, get in touch with the Control Metrix team for a consultation. For more information or to speak to one of our product specialists, contact us at hello@control-metrix.com or give us a call at 01823 761 309
