About us
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With smartmfgs.com we are dedicated to empowering small manufacturers to welcome the future of smart manufacturing. With over 30 years of pioneering experience in automation, process optimization, and digital transformation, we help you unlock new levels of productivity and efficiency.
Our team consists of passionate engineers and consultants who bring deep industry knowledge and hands-on expertise in time studies, downtime analysis, and innovative automation solutions. We work closely with you to tailor strategies that save labor and production time while driving sustainable growth.
We believe that smart manufacturing is not just about technology—it’s about transforming how you work, collaborate, and innovate every day. Together, we guide your journey with reliable support and real-time insights so you can succeed. in a competitive market.
This approach highlights Our extensive experience, technical skills, collaborative culture, and customer-centric focus.
A few things we’re great at
“Transforming small manufacturers through tailored automation, insightful time studies, and measurable results.”
Intelligent Automation
“Harness the power of intelligent automation to streamline production, reduce downtime, and drive smarter, faster manufacturing decisions.”
Immersive User Interface
“Step into a new era of manufacturing—where immersive interfaces empower smarter, faster decisions on every production line.”
Real-time Collaboration
Real-time collaboration drives synchronized actions, turning data into decisions that accelerate your smart manufacturing journey.”
Dynamic Design Showcase
Why Choose Us
When you partner with us, you’re not just getting a team—you’re gaining over 75 years of collective expertise. Our commitment to excellence is proven by our Lean Six Sigma certifications, our master’s degrees in mechanical engineering, and our dedicated PLC automation experts. This powerful combination of skills and experience allows us to solve your toughest challenges with unmatched precision and innovative, forward-thinking solutions.
Our Projects
Showcasing Innovative Solutions with Excellence in Design and Precision Execution”
Material Savings
Material Savings Through Optimized Die Cutting Layout
This project focused on saving very expensive material by optimizing the die cutting layout. The original job specification was to cut two equal parts, each measuring 22.5″ x 84″. Initially, the original die cut produced 10 pieces per sheet.
By redesigning the layout and creating a new custom die, we optimized the cutting process to achieve 14 pieces per sheet, using the same amount of material as before. This resulted in 4 additional pieces per sheet without increasing material consumption.
Key Results:
Production increase: 40%
(Increased from 10 pieces to 14 pieces per sheet)
Material saving per piece: 28.57%
(More pieces produced per sheet means less material used per piece)This optimized die cutting layout not only enhanced production efficiency but also significantly reduced material costs, making it an excellent example of cost-effective manufacturing with sustainable material usage.
Designed
Hot Pen Foil Marking Solution
CNC-Designed Hot Pen Foil Marking Solution with Step-by-Step Process
In this project, the customer requested a CNC-based hot pen foil marking solution. I designed a custom CNC engraving process that can be effectively used for hot pen foil marking applications.
The project included designing and developing precise CNC engraver tailored for Hot Pen Foil Marking with a hot pen tool. Additionally, I created a detailed, step-by-step process guide to demonstrate how to perform hot pen foil marking efficiently and consistently.
Key Highlights:
- Custom CNC engraving design optimized for hot pen foil marking
- Developed a practical and repeatable step-by-step procedure for successful foil transfer
- Ensures high precision and quality in foil marking on various substrates
- Enhances customer productivity and process reliability by providing clear instructions
This project demonstrates how CNC technology can be leveraged to improve traditional foil marking methods, integrating precision design with clear operational guidance to achieve excellent results.
Optical Sensor for Custom Dashboard
Optical Sensor Counting and Custom Dashboard for Cycle Time and Downtime Monitoring
In this project, the customer required a precise and automated system to count parts using optical sensor technology. I designed and implemented an optical sensor counting solution integrated with real-time monitoring of cycle time and downtime.
A custom dashboard was developed to display all relevant production details clearly, including part counts, cycle times, downtime occurrences, and overall equipment effectiveness (OEE) metrics. This setup provides operators and management with instant insights to optimize production efficiency and quickly address downtime issues.
Key Features:
Accurate part counting using optical sensor for high reliability
Real-time monitoring of cycle time and downtime for comprehensive production tracking
Custom dashboard displaying live production data, downtime analytics, and performance indicators
Enables quick decision-making and continuous improvement on the plant floor
Enhances production visibility and operational control to reduce losses and improve throughput
100% Scrap-Free Fiberglass Washer
The client required a solution to guarantee there was no scrap remaining on round fiberglass washers after die cutting. Removing every trace of scrap from fiberglass material was highly challenging due to its tough composition and the small, intricate washer shapes.
Innovative Solution:
Designed an extra knock-out feature specifically targeting the central scrap area of the washer during die cutting.
Integrated a shaker mechanism into the process: as washers drop after being cut, the shaker agitates them and ensures any remaining scrap or hanging material is automatically released.
The combination of precision knock-out and mechanical agitation replaced the need for manual labor, delivering a fully automated, efficient process.
Showcase & Results:
Achieved 100% scrap removal—all washers arrive completely clean, meeting strict customer specifications.
The new process eliminated the previous need for tedious manual scrap removal, reducing job completion time from 3 days to a matter of hours or less.
Production yield increased, labor costs dropped, and product quality improved significantly.
Reliability and consistency in output satisfied even the most demanding customer requirements.
Key Benefits:
Guaranteed scrap-free washers for every batch.
Dramatic reduction in labor hours and job turnaround time.
Automated solution ensures consistent quality and operational efficiency.
Enhanced customer satisfaction and competitiveness by meeting the highest professional standards for fiberglass washer manufacturing.
Our team
Our team is a dedicated group of experienced engineers, consultants, and problem-solvers passionate about helping small manufacturers succeed. We combine technical expertise in automation and process improvement with a hands-on approach, delivering reliable support every step of your digital transformation journey.
Shekhar Shroff
Manufacturing Engineer
