Published: November 05, 2015  Updated: April 16, 2025

The Unexpected Persistence of Manual Manufacturing and the Indispensable CMMS

In an era dominated by automation, you still have the unexpected persistence of manual manufacturing. How can a computerized maintenance management system assist these companies? Let's explore that topic.

Yes, some manufacturers still craft their products primarily by hand. This dedication arises from diverse motivations, ranging from practical necessity to a deep appreciation for the unique quality imparted by human skill. While the onward march of robotics and automated systems is undeniable, several notable industries continue to value and rely on meticulous manual processes.

The Art of Hand-Assembled Technology

Consider the ubiquitous Apple iPhone and iPad. Surprisingly, these sophisticated devices undergo significant hand-assembly. The creation of an iPhone involves an astounding 141 distinct assembly steps, each demanding precision and human oversight. The larger iPad requires even more intricate work, with over 300 dedicated individuals meticulously piecing together each unit. This extensive human involvement underscores a commitment to quality and a level of detail that, at least currently, automated processes cannot fully replicate. The care invested in each device ensures a tangible sense of craftsmanship reaches the end consumer.

Detailed Look at Apple's Assembly Process

The 141 steps involved in iPhone assembly encompass a wide array of intricate tasks. These include the careful placement and connection of numerous internal components, the secure fitting of the device's various modules, and rigorous testing at multiple stages. Skilled technicians handle delicate wiring, ensure proper alignment of screens and cameras, and meticulously fasten tiny screws. Each worker often specializes in a specific set of tasks, contributing their expertise to the overall creation of the device. This division of labor, while part of a larger production line, still relies heavily on manual dexterity and visual acuity.

Similarly, the over 300 steps for the iPad involve a comparable level of intricate assembly, highlighting the sheer scale of human effort involved in producing these popular gadgets. This hands-on approach allows for a level of tactile feedback and immediate quality control that can be challenging to achieve with purely automated systems.

The Timeless Craft of Glassblowing

Another industry deeply rooted in manual production is glassblowing. This ancient craft, often showcased at Renaissance fairs and within vibrant art districts, demonstrates the transformative power of human breath and skill. Glassblowers heat raw glass to precise temperatures, rendering it malleable. They then skillfully blow air into the molten material while simultaneously shaping it with specialized tools. This demanding process involves numerous complex and time-sensitive steps, each requiring years of practice to master.

The unique characteristics and artistic flair inherent in hand-blown glass distinguish it from mass-produced alternatives. Products created through this method range from delicate lighting fixtures and whimsical figurines to elegant bowls, vases, and unique art pieces, each bearing the mark of the individual artisan.

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The Intricacies of Shaping Molten Glass

The journey from raw glass to a finished piece involves a fascinating interplay of heat, air, and skillful manipulation. Glassblowers utilize various tools, including pipes for blowing, jacks for shaping, and paddles for flattening. Maintaining the correct temperature of the glass is crucial, as it dictates the material's viscosity and workability. Each breath and movement of the glassblower directly influences the final form, demanding exceptional hand-eye coordination and an intuitive understanding of the material's properties. Decorative elements, such as swirls of color or intricate patterns, are often incorporated during the shaping process, further highlighting the artisan's expertise. The inherent variability in hand-blown glass contributes to its unique appeal, with no two pieces ever being exactly alike.

The Precision of Hand-Made Timepieces

The world of horology also features manufacturers who continue the tradition of hand-making intricate Swiss and German watches. These timepieces, often containing a multitude of minuscule moving parts, demand meticulous assembly to ensure their precise and reliable operation. While modern technology offers automated methods for watchmaking, certain companies uphold the value of human craftsmanship, both as a matter of tradition and as a key element of their brand identity. Glashutte, for instance, emphasizes the significant human effort and dedication invested in each of their unique creations. This commitment to hand-assembly underscores a dedication to quality and precision that resonates with discerning clientele.

The Delicate Assembly of Watch Movements

The assembly of a mechanical watch movement is an exercise of extreme precision. Watchmakers use specialized tools and magnifying devices to handle and position hundreds of tiny components, including gears, springs, and screws. Each part must be meticulously placed and adjusted to ensure the smooth and accurate functioning of the timepiece. This process often involves intricate lubrication and careful calibration. The human touch allows for minute adjustments and a level of quality control that can surpass automated systems when dealing with such delicate mechanisms. The expertise of skilled watchmakers ensures that each hand-assembled watch represents a testament to horological artistry and engineering.

The Indispensable Role of a CMMS Across Manufacturing

Regardless of the primary manufacturing process–whether it involves intricate hand assembly or relies heavily on automated machinery–one technological tool has become virtually indispensable: a Computerized Maintenance Management System (CMMS). This software serves as a central hub for managing a facility's assets, tracking inventory, and scheduling and managing maintenance activities. The adoption of a CMMS brings significant advantages to all types of manufacturing operations, fostering efficiency and reducing downtime.

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CMMS for Hand-Assembly Operations

Even in facilities where the primary production relies on manual labor, a CMMS can play a vital role. While there may be fewer complex machines requiring constant upkeep, these facilities still possess essential assets such as tools, equipment, and the physical plant itself. A CMMS aids in tracking the inventory of hand tools, ensuring their availability and proper maintenance. It can also manage the upkeep of the facility's infrastructure, including lighting, HVAC systems, and safety equipment, creating a more productive and secure work environment for the assembly teams. Furthermore, a CMMS can assist in scheduling routine inspections and addressing any maintenance needs that arise within the facility, preventing disruptions to the manual assembly processes.

Better Inventory Oversight

Even companies specializing in hand-crafted products need inventory. With a CMMS, you have better oversight and organization of inventory management. Set up specific locations in the storage room for each part and supply. The system auto-tracks quantities and can generate purchase requests when those levels drop below a threshold.

Subsequently, you can use the CMMS for more than maintenance and inventory. Make a database for vendor information, standardize purchase orders, process receiving, and handle invoicing.

Centralized Data and Improved Decision-Making

A key benefit of implementing a CMMS is the centralization of critical maintenance data. This provides facility managers with valuable insights into equipment performance, maintenance costs, and potential areas for improvement. Reports generated by the CMMS can help identify recurring issues, track key performance indicators (KPIs) related to maintenance, and inform strategic decision-making regarding equipment upgrades or replacements. These reports allow manufacturers, regardless of their production methods, to make informed choices that positively impact their bottom line and operational effectiveness.

Ultimately, whether a manufacturer embraces the precision of robotics or the artistry of human hands in their production processes, the strategic implementation of a CMMS offers a tangible advantage. This technology acts as a cornerstone for efficient facility management, ensuring the smooth operation of equipment, the availability of necessary resources, and the overall productivity of the manufacturing environment. The digital age offers tools that complement both tradition and innovation in the diverse world of product creation.

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