Looking to improve efficiency? Here are the top areas to target first

Improving efficiency is about more than just increasing speed – it’s about making processes leaner, reducing waste, and ensuring that every component of the operation works together seamlessly. Whether you’re running a fully automated production line or integrating automation into an existing setup, targeting the right areas first can yield immediate benefits. And with more than 20 years of experience to our name, we know a thing or two about the subject here at LED Controls – here’s what we’d suggest!
Energy consumption
Energy costs can account for a significant portion of factory overheads, and inefficient use of power can lead to unnecessary expense. One of the most effective ways to reduce energy consumption is through variable speed drives (VSDs), which enable motors to adjust their speed based on demand – effectively preventing excess energy use when full power isn’t required. Reducing energy waste in motor-driven applications alone can lead to noticeable savings over time.
Similarly, switchgear plays a crucial role in controlling and distributing electrical power efficiently – so bringing in modern, well-monitored switchgear ensures a more stable and controlled power supply, reducing the risk of faults.
It also may be worth considering smart energy monitoring systems track real-time consumption and highlight inefficiencies. Identifying patterns makes it easier to adjust processes, avoid energy peaks, schedule energy-intensive operations at off-peak times, and cut overall consumption.
Production bottlenecks
Even the most advanced automation system can be hindered by bottlenecks. In many cases, these issues can often be traced back to equipment limitations, outdated processes, or poor synchronisation between different parts of the production system.
Regular data analysis is key to identifying bottlenecks. Smart sensors and analytics software provide real-time performance metrics, helping manufacturers pinpoint where slowdowns occur and take corrective action before minor inefficiencies escalate into major production halts.
On that note, well-chosen programmable logic controllers (PLCs) can be particularly useful in addressing these inefficiencies. They automate and regulate machine processes, ensuring production lines run smoothly with minimal manual intervention. They can be programmed to manage material flow, balance workloads between machines, and react to fluctuations in production demand.
Machine downtime
Unexpected equipment failures are one of the biggest efficiency killers in factory automation; responsible for lost production time, costly repairs, and disrupted workflows.
One of the best ways to minimise the effect on your business is to ensure that you’re operating on a principle of preventative maintenance rather than reactive maintenance. Reactive maintenance refers to the practice of essentially fixing problems as they arise. Predictive maintenance on the other hand focuses more on anticipating issues, and dealing with them before they become serious problems.
Preventative maintenance is often put off because it often involves spending money to inspect or fix issues with machines that aren’t technically “broken”. On the other hand, it’s almost always cheaper in the long-term, as it costs less to fix minor issues than it does to fix them after they’ve developed into major problems.
Preventative maintenance uses historical and real-time data to forecast potential failures. Machine learning algorithms can identify patterns that indicate a developing fault, allowing factories to schedule maintenance at optimal times rather than waiting for an emergency. This not only reduces downtime but also extends the lifespan of critical equipment, leading to lower operational costs in the long run.
Staff integration
Automation is most effective when human staff and machines complement each other rather than operate in isolation. While automation can handle repetitive, precise, and high-speed tasks, staff are still needed for problem-solving, quality control, and system oversight. The key is ensuring that people and machines interact seamlessly.
Human-machine interface (HMI) technology plays a crucial role in bridging this gap. User-friendly control panels and automation software allow staff to monitor and adjust machine operations without complex programming knowledge. This improves responsiveness and ensures that any issues can be resolved quickly.
Training is another critical factor. It’s obvious, but worth mentioning – staff who are properly trained in automation processes are generally better at identifying inefficiencies and suggesting improvements.
Those are just a couple of the most critical points that spring to mind! We’ll leave you to make the final decisions as to what to implement. Here at LED Controls, we’ll stick to doing what we do best. With more than two decades of experience behind us, we supply a wide range of components, including programmable logic controllers, variable speed drives, and motor control gear equipment. Feel free to explore what we have available – and of course, if you ever have any questions or need any advice, you can always give us a call on 01706 242050. Our team is here to help!