Some amount of waste is inevitable in the automotive industry, but here at American Manufacturing, we are always looking for new ways to reduce waste and increase production efficiency. Not only is waste reduction important for the environment, but it’s also crucial in how we improve our bottom line and deliver to our customers, with innovative approaches that reduce all manner of waste, from scraps and landfills to time and labor.

Automotive Then and Now: How Waste Reduction Has Evolved

Waste reduction has become a hot topic in the automotive world as companies seek better ways to handle production that are more environmentally conscious. Beyond emerging trends in automotive manufacturing like electric or hybrid vehicles, automotive companies are looking for ways to reduce their carbon footprints throughout production.

Renewed Focus on Repairs

Historically, automotive production has involved a lot of new builds, constantly looking for ways to improve and enhance vehicles rather than seeking longevity and improvements to existing models. This has changed quite a bit over the past few years, especially following the supply chain issues of 2020 that limited automotive production significantly. Today, automotive companies have shifted their perspective to encompass repair work—fixing what is fixable instead of simply scrapping it and making something new.

Reusable Packaging

Automotive plants have traditionally kept parts stored in cardboard boxes as a fast and cheap means of transporting items. But these boxes aren’t sustainable, and rarely last for more than one use. Cardboard is still practical for pilot runs of a new model when they aren’t certain of material handling needs yet. But many plants have formed excellent processes for responsible recycling of these packaging materials.

After a pilot run is complete and a new model is ready for regular production, automotive plants have moved away from cardboard and started investing in sturdy, reusable containers and industrial racks to store, move, and organize parts throughout production.

Innovative Approaches to Waste Reduction in Automotive Production

In addition to broader changes in the automotive industry, here are a few particularly innovative approaches to reducing waste in production:

Servo-Driven Machines

It may come as a surprise to think about robotics as reducing waste considering the high amount of electrical power required to run them. But servo-driven machines and assembly lines actually draw a lot less power overall than older mechanical or hydraulic systems. The input power required is much lower, reducing energy consumption in manufacturing. Servo motors also work at a much faster rate for greater efficiency and accuracy.

Environmental Health and Safety (EHS) Measures

There are many different standards for environmental health and safety (EHS), and some of the best standards across various industries are put forth by the International Organization for Standardization (ISO). One innovative approach to EHS that we’ve noticed is ISO 14001, which Tesla in particular is committed to as a structured approach to improving environmental performance.

Scrap Reduction with Bending Cells

At American Manufacturing, one of the biggest sources of physical waste we deal with every day is scrap. As an automotive parts manufacturer who cuts and bends parts from sheet metal, there will always be scraps leftover at the end of the process, but our new Trumpf robotic bending cell has significantly reduced the amount of scrap produced with each part.

With mechanical or hydraulic presses and bending cells, just setting the press for a new part often produces a lot of waste as it can take a few attempts to get the fit right. The Trumpf cell uses an ACB laser to measure the angle of a bend and make sure the exact amount of force is used to produce a good part on the first or second try!

Enhance Your Automotive Production Experience

At American Manufacturing, we’re passionate about exploring the latest and greatest technologies to improve production, product quality, and waste reduction throughout our manufacturing processes. Contact us to learn more about our services and how we can help improve your builds.