Hayes Manufacturing Integrates Robotics to Strengthen Lean Practices and Maintain Cost Stability

Hayes Manufacturing has taken a major step forward in its lean manufacturing journey by integrating advanced robotic technology into its Hex Flex plate product line. As labor markets remain unpredictable and the demand for precision continues to grow. Hayes is staying ahead by automating critical parts of its production process without compromising quality.

The Fanuc Robot M-200iD/25 loads and unloads every Hex Flex plate with exact, repeatable precision. It also performs 100% inspection of each part and captures valuable data for analysis. Ensuring that only top-quality products leave the cell. This level of consistency is difficult to achieve manually and reinforces Hayes’ commitment to lean, high-performance operations.

One of the most significant advantages is time. The robot can run for up to three hours without human intervention, providing valuable unmanned machining time.

“Time is the biggest benefit, As long as there’s product, the robot is working. It loads the same way every time, and it doesn’t stop.” – Jeff Miller, Director of Manufacturing & Quality

Beyond operational efficiency, the robot plays a key role in cost control. It helps Hayes maintain stable production costs during labor shortages and can help offset rising material costs by lowering overall production expenses. It also enhances employee safety by reducing manual handling and minimizing the risk of accidents.

By investing in automation that supports lean manufacturing principles, Hayes Manufacturing ensures consistency, safety, and long-term resilience in a competitive market.