High-Mix, Low-Volume (HMLV) electronics manufacturing comes with a unique set of challenges: producing a wide variety of products in small batches, switching jobs frequently, and maintaining high quality, all while keeping costs under control. Traditionally, these environments relied heavily on skilled manual labour due to their complexity and variability. But recent advances in automation are making it a more accessible and valuable investment, even for HMLV operations.
Is automation truly worth the effort in HMLV projects? Explore the key benefits, common hurdles, and practical strategies for electronics manufacturers in this article.
A Closer Look at HMLV Manufacturing
HMLV manufacturing is typically associated with:
- A high diversity of product variants, each with different components and processes;
- Small batch sizes, often with just dozens or hundreds of units per run;
- Routine frequent switches between jobs;
- High quality demands and costly errors;
- Limited space on the production floor and the need for adaptable skills.
The nature of HMLV has historically made automation difficult to justify compared to high-volume production, but the technological innovation is shifting the trend.
Why Automation Makes Sense in HMLV
Automation can bring the flexibility, precision, and speed that are needed to keep up with the demands of HMLV production.
1. Flexibility for frequent changeovers
Modern robots, especially collaborative robots (cobots), are designed for rapid reprogramming and redeployment. Unlike traditional automation built for large-scale runs, cobots are safe to work alongside human operators and can be quickly taught new tasks.
2. Consistent quality and precision
Automated systems reduce the risk of human error. Machine vision and real-time monitoring ensure precise assembly and enable early detection of defects, helping manufacturers maintain quality without slowing down production.
3. More output without losing agility
Automation streamlines workflows and supports a steady pace of production, even with frequent changes in product types. It helps manufacturers scale output while preserving the adaptability needed to meet changing demands.
4. Smarter supply chains
Automating inventory and logistics helps to improve the availability of components. This is essential for reducing delays, improving visibility, and coordination across the supply chain.
5. Stronger ROI
Today’s automation solutions are more affordable and modular than in the past. Lightweight robots and plug-and-play systems lower upfront costs and reduce rework and labour expenses. This makes automation viable even for smaller batches.
6. Support for customisation and innovation
As customer expectations grow, automation helps manufacturers to offer tailored products without slowing down. It simplifies handling different configurations and supports faster prototyping cycles.
Key Challenges to Consider
Despite its advantages, automating HMLV production comes with several potential challenges manufacturers should be aware of:
1. Demand for expertise
Managing a wide range of parts and tasks requires systems that can adapt quickly. Programming, maintenance, and changeovers all demand thoughtful planning.
2. ROI considerations
The return on investment in HMLV depends on choosing flexible, scalable systems. Fixed, single-purpose machines are often too expensive and inflexible for low-volume work.
3. Integration hurdles
Merging new automation with existing manual workflows isn’t always easy. Manufacturers must also train staff to work alongside these technologies and embrace a culture shift.
4. Space limitations
Many HMLV facilities have space constraints. Compact, mobile automation solutions are needed to make deployment feasible without major infrastructure changes.
Proven Tactics for HMLV Automation
Leading electronics manufacturing service (EMS) providers like Poland-based Assel know that success in HMLV automation requires the right approach:
- Choosing modular, flexible automation platforms that can be quickly adapted to new products without major retooling;
- Combining human expertise with modern automation systems like collaborative robots, smart sensors, and machine vision for optimal results;
- Creating predictable processes to reduce complexity and speed up changeovers;
- Digitalising inventory and production monitoring with real-time tracking;
- Investing in training to help operators work confidently with new tools, while reducing errors and improving the adoption of the new technology;
- Aligning the automation roadmap with regional infrastructure and labour market trends.
Final Thoughts: Is Automation Worth It?
Yes, but it has to be approached strategically.
Today’s automation is more accessible and better suited to HMLV than ever. Despite challenges, the efficiency, consistency, and agility it brings make it a smart investment for future-focused manufacturers.
To partner with a contract manufacturer with broad experience in HMLV, visit asselems.com.
