Wednesday, November 29, 2017

The high value of manufacturing efficiency

Rockwell Automation recently rejected a buyout offer from Emerson Electric of $29 Billion. That's a lot of dough, and that's a lot of NO.
(See the full story here at IndustryWeek.)

Rockwell claims they see more potential in expanding their innovative products and entering new markets with their manufacturing technology. Analysts will surely note that there are many more complex unseen factors impacting this proposition.

The future of manufacturing appears healthy, but competitive
One thing about this story is clear: manufacturers see a healthy future, and they are investing heavily in advanced processes to be sure they can be competitive. As indicated by this news story, I can think of 29 Billion reasons that support this claim.

Toyota, the standard-bearer of manufacturing efficiency for the past 50 years, is designing new factories to be more nimble and flexible. They are developing their New Global Architecture manufacturing system to focus on customized production runs of 1, 2, 3 or 4 units at a time rather than lots of 50 or more.

If you also work with many SKU's, you may want to evaluate your process with GSG. The experienced team of engineers and industry veterans may be able to help you improve your efficiency and productivity.

3 keys to competitive manufacturing:

Know your OEE factors
The Greenlight XT monitoring system from Gribetz can automatically track machine performance, piece-counts and other metrics to keep you informed of productivity in real-time. It work on your own internal network or you can access data from anywhere via the Internet. Best of all - it can be added to nearly any existing equipment with no additional machine programming.

Eliminate non-value-add touches
Systems like the Gribetz DST-60 puts more value into you product. Every time a worker touches your product without improving it (adding value), you lose money. Each time it's manually lifted, moved, loaded, unloaded... diminishes the value of that product. The DST-60 automatically brings the quilt panel to the flanger/serger operator so his efforts can be focused on value-adding processes.

Use flexible equipment for customized production
The newest quilter from Gribetz is the Spectrum, a revolutionary mattress quilter with 15 independent sewing heads! You can diversify your panel production mid-stream because no time-consuming needle changes are required to change panel designs. The computerized system automatically directs each sewing head to operate as needed. The Spectrum operates with a real sewing speed of 1400 RPM, so you can have a flexible production schedule and maintain high-volume production!

These are just three ways to improve your manufacturing process. As Rockwell and Toyota would confirm, there are many more variables, so consult with a GSG rep soon to see where to get started on the many possibilities from GSG.

Tuesday, November 14, 2017

Lasting innovation changes how things get done.

If you've visited Google today, you've surely seen this Google Doodle. It's the 131st anniversary of the patent filing for the paper hole punch. Congratulations, Friedrich Soennecken, you've made the world a better place through your innovation.

Thousands of patented innovations have fallen by the wayside long before their 131st anniversary. To succeed, innovation must meet the following criteria:
  • Clearly solve a widespread problem
  • Work efficiently and effectively for an enduring time
Gribetz International introduced a new innovation in 2017 - the Spectrum quilter. It's a unique mattress quilter with 15 individual operating sewing heads. They can automatically turn on and off for different pattern designs without requiring time-demanding needle changes. All of this amazing production is accomplished at a sewing speed of 1400 RPM!

Gribetz Spectrum with programmable needle pattern production

Here's how it meets the previously listed criteria of success:

Problem(s): solved
Today's mattress manufacturers must meet new demands for speed and flexibility in ever-changing production runs. Traditional fixed-needle quilt machines force a manufacturer to either accept costly downtime to change needle settings with some pattern changes, or forfeit production flexibility by only committing to a limited number of pattern design choices. Using a Gribetz Spectrum, production up-time improves with no needle setting changes, and you can make your production schedule more flexible and responsive to change, providing more design choices for more customers.

Enduring effectiveness
It's a Gribetz! That's one of the most trusted names in mattress machinery, and that's because their quilters have been proven to work for generations of business owners. We can't match the enduring legacy of Friedrich Soennecken yet, but we're headed there. Gribetz has been innovating mattress quilting for over 75 years!

Learn more about the new Gribetz Spectrum here today, and look for this mattress production innovation's Google Doodle in about 130 years!

Friday, September 29, 2017

Is your Productivity Rate flat-lining?!

As stated here many times, good productivity is vital to the health of your mattress manufacturing business. It is one of the purest measurements of your company's success because it weighs the true product value you get out of the resources you invest in your business.

The chart below shows the Productivity Index Rate specifically for Furniture Manufacturers (NAICS code 337) from 1996 to 2016. Overall, we've come a long way, but that's not all it tells us. Twenty years ago the productivity rate was expanding very rapidly, and though it is still showing some growth, it has become relatively flat in recent years.

(Based on statistics from the Bureau of Labor's Productivity and Labor data series IPUEN337___L000)
Obviously many impacting factors come into play; changes in product value, employment levels, just to name a couple biggies. So you can really improve your productivity rate by raising the selling price of your final product, and if you can do that - more power to you! Instead, most manufacturers are being pressured to competitively reduce their selling price, so that makes productivity improvements even more valuable than ever.

Global Systems Group has developed many new technologically advanced mattress machine systems to keep your factory from flat-ling. Multi-tasking operations (more work from less labor) can quickly point your productivity rate upwards.
Porter PE-504/DO with flange attachment
This Porter PE-504/DO is a roll-fed serging machine to overedge each side of border material AND it can automatically add flange behind the serging operation. This improves your worker's productivity in two ways! Since it is fully automated, your worker can perform another operation while this process is working, and the additional flange attachment eliminates that downstream operation altogether.

Gribetz DST-60 de-stacker robot

The Gribetz DST-60 robotic quilt panel de-stacker automatically loads panels into the flanger workspace without any need for operator labor. Reducing non-value-add touches is another valuable productivity factor because it keeps your worker focused on improving product value rather than sucking value out with unnecessary labor tasks.

Don't fall behind the curve in the area of factory productivity. Visit the GSG website,, to find many more high-production systems for your mattress factory.

Friday, September 22, 2017

What is Productivity? (The simple answer, please...)

(Video courtesy of the US Department of Labor's Bureau of Labor Statistics See:

Sometimes it's helpful to get back to the basics. This simple primer video will make you ask, "So how's my Output/Input ratio these days?" (Hint: the bigger the value, the better) There are many complex methods and practices to achieve this, but that's what it boils down to.

Global Systems Group wants to help mattress manufacturers make more products with less effort. That way, you make more profit, and that way - well - that way, you make more profit! That's a simple concept too!

Making the production process simple for your operators is a quick, basic way to improve your factory's productivity. These simple machine are perfect examples of this:

Gateway Systems Mattress Master Optima
Manual tape-edging is hard work. Automated tape-edging with a Mattress Master Optima machine is simple work. It automatically moves the heavy bed for the operator and built in features ensure good finish quality.

Porter EST-501 Flange Machine
The EST-501 simplifies the crucial task of serging/flanging mattress quilt panels. The belts are synchronized with the sewing speed of the sew-head and they automatically turn the mattress for clean cornering. A de-skilled operation and comfortable work station can make any operator more productive in a short time.

Gribetz Paragon SL straight line quilter
Here's a simple machine to greatly increase your productivity. This new Gribetz Paragon SL quilter is designed for the mattress producer that makes a huge capacity of "channel quilted" beds - that is simply straight line sewing with no Tack and Jump patterns or side-to-side movements. Sewing at 1750 RPM, it's the fastest mattress quilter ever!

Sometimes in manufacturing businesses we overthink things. It's refreshing to make a simple analysis of our productivity, and GSG has some simple solutions to help you do it better.

It's simple - contact GSG as soon as you can to improve your Output/Input ratio.

Wednesday, August 30, 2017

GDP growth was revised UP. What's up with your growth plans?

Headline: "US second-quarter GDP growth revised up to 3%"
This news about recent US GDP growth is great news for the US macro-economy, but it does hint at one possible drawback to your own economic plans. See if you notice what I'm talking about in the following excerpt from the news story:

"...Strong growth and a labor market that is near full employment support views the Federal Reserve will lay out a plan to start unwinding its $4.2 trillion portfolio of Treasury bonds and mortgage-backed securities next month and increase interest rates in December..."(full story: )

You most likely noticed that five word warning tucked into that article. This caution only applies to those requiring financing to help them ramp up production to meet demand in the growing economy. As the news article indicates, consumer confidence is rising and employment is nearly full. That means more shoppers will be in the market to buy products like yours - or your competitors' products. 

Be prepared for more customers AND more competition with new advanced equipment, and get it now while interest rates are still in your favor.

Here are two mattress factory items that should be at the top of your list:

1. ) Waste-Exit vacuum-powered waste removal
This system starts paying for itself immediately with greater plant efficiency that will help your bottom line profits NOW and long into the future.

2.) Paragon M+ quilt machine
This machine is the most versatile available. It's everything you need: fast sewing speed, strong enough for thick panels, and Posi-Trim T&J thread trimming that eliminates non-value-add touches in your quilt department.

If you need to invest in future growth for your mattress business, now's the time, and if you're looking for the best ROI for that investment, now's the time to contact GSG!

Friday, August 25, 2017

Are you planning to keep pace with competitive factory productivity?

"...New orders for key U.S.-made capital goods rose slightly more than expected in July and shipments surged, pointing to an acceleration in business spending early in the third quarter...." - excerpt from news article (read whole story here:

Your fellow manufacturers are moving forward with positive expansion plans... are you?

Obviously there are pockets of both growth and contraction from month to month, but the overall global outlook for manufacturing is GROWTH. Recent reports from Europe to SE Asia have indicated manufacturing economy expansion and companies are gearing up for it with new, advanced equipment to keep up with this upward trend.

GSG has been moving forward with new partnerships to make your production more efficient and profitable. We've also developed new mattress equipment debuted at the Interzum Trade Fair, in May.

Don't rush into a machinery purchase from GSG! 
(...that's right, you heard me correctly.)
We have decades of experience in mattress manufacturing, and we've been meeting with mattress manufacturers around the world lately planning for improved production. We want to take a moment with you to apply this experience in order to develop a plan for your improved processes. (.. and then you can make the most appropriate machinery purchases from GSG!)

Gribetz Spectrum
Maybe you're not ready to buy our new Gribetz Spectrum quilter today, but you may be ready to start a plan today. Contact your local GSG representative to schedule a planning meeting today so you can prepare for the global manufacturing changes currently underway.

Thursday, August 3, 2017

US factory expansion is up (good) and so are raw goods costs (bad)!

US Factory Gauge Continues to Signal Solid Expansion in July

...While the ISM index settled back from a June level that was the second-highest since 2011, it remains above the average over the past year, as are its three main gauges. The figures signal that optimism about the economy is enduring among American businesses even as prospects dissipate for swift changes on tax and infrastructure policy from Washington lawmakers.

 Goods producers are sustaining progress that’s been building since 2015. Steady U.S. consumer and business demand, along with a recovering global economy, are allowing manufacturing to hit its stride.

 A pickup in the ISM’s prices-paid index indicates more factories also reported paying higher prices for inputs and raw materials last month, also a reflection of improving world demand... 

- excerpt from recent article  

(read full story here:

That's the recent news from IndustryWeek magazine. Overall, it's good news for manufacturing, but pay attention to the last Key Takeaway in the final paragraph. It specifies an increase in Prices Paid Index. This story indicates that production is strong, optimisim is strong, but your raw materials cost is going to take a bite into your profit margins. 

Unless you make some adjustments... As the world's economy growth and demand improves, your material costs will continue to swell. You may not have the leverage to force your supplier to keep raw goods prices down, but you can offset those costs with some manufacturing adjustments.

When your raw goods increase you have to counter that by decreasing your scrap waste and decreasing the cost to convert it to finished goods. That's achieved through improved efficiencies.

One way the new Gribetz Spectrum quilter does this is by reducing downtime required of changes to needle settings. Since the Spectrum's unique design uses 15 independent sewing heads, NO needle setting changes are necessary to switch from one pattern design to another! Each sewing head can be independently controlled and automatically turns off/on as needed.
New Gribetz Spectrum with 15 unique sewing heads

With the Spectrum, you can create the most unique product designs to be competitive in this increasingly competitive industry while still maintaining a profitable bottom line with better production efficiencies. Besides reducing downtime, you can also increase your daily yield sewing at 1400 RPM on the Spectrum!

GSG has equipment to improve your bottom line through improved productivity and efficiencies in every part of your mattress factory. Click here to learn more about all our New Products.

New Products from GSG