RLP - Repeating Layer Process

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For over a century, any manufacturing process built, follows the Linear Assembly Process method for the design of manufacturing systems. Linear Assembly has been used for over 120 years and is widely known as the only way to build manufacturing processes. Throughout the history of manufacturing, there've been many challenging products, which became very expensive to manufacture, simply because there is only one way to do it. Since the Assembly Line is the only method known in the industry, the development focus of all industries was to make equipment smaller, faster, and more complex, to be able to build high-speed and high-capacity machines. High speed equipment and complex machines supported manufacturing for long time, but they always come with expensive price tag, even though, that is the only thing available. With the inflated cost and high complexity, it was only possible for large organization to get involved in manufacturing, which mostly exclude the small business category.   

We introduce a novel Manufacturing process design method that can serve as an alternative process to the Assembly Line method. Utilizing a special mathematical property among over 70% of all manufactured products. RLP (Repeating Layer Process) is a novel manufacturing process that allows for new manufacturing capabilities. The Repeating Layer process introduces many advantages, like; Lower Time to Market, Lower Initial System Cost, Lower Operations Cost, 95% - 100% System Availability, System Scalability to over 5X the initial Capacity, Incremental investment, Smaller real Estate, and more benefits that were not possible in the last hundred years. The Repeating Layer Process helps a wide range of product families and across all industries, like; Automotive, Pharmaceutical, Food and Beverage, Energy, Electronics, and more. Repeating Layer Process will be used for the products that have, a multiple of sub-components or operations, which repeat for a defined number. There are many examples in this category of products through all industries, like Battery Modules / Packs, Pharmaceutical containers, food and beverage bottled and canned products, Solar Panels, many more that we know today, and even more that can be modified to apply. Utilizing the Repeating Layer process will take the manufacturing capability for this type of products to a different level of manufacturing efficiency. Our Novel Manufacturing Process dose not only improve production, but also promotes Quality, Efficiency, Scalability, Modularity, and More.  

Repeating Layer Process system design is scalable, where you can add more machines to scale the production at any time, and with minimal down time, with no changes to the existing equipment in the system. keeping in mind that we're not adding the same number of machines in the initial system.

For example, we've designed a system that has Five machines for initial capacity of 400,000 MPY (Module per Year) and scaled it to 800,000 MPY by adding two more machines only. The Repeating Layer process is designed to make scalable systems to serve both low and high production requirements, as the market requires.   

With these capabilities, we can build a low-cost production system in under 50% of the time, with low production capacity, and we can continue to scale the production as we find necessary to over 10X of the linear process capacity. This production scalability allows us to always make the right investment that is supported by market demand, and at the same time we can scale the production anytime much faster with a smaller footprint.   

For the first time in any industry, we introduce the scalable Production Capacity. Where you can build a low-capacity system for low investment, and scale the same system as market demand increases, without obsoleting the equipment for earlier stages. The Capability for incremental scalability allows for rapid and stable growth of your business, from the Engineering, Manufacturing, and Financial Domains. 

The Capacity of the Production System can be scaled to Over 10X The Initial Capacity, By Expanding the Same System. This capability allows for higher efficiency in the use of capital investment, higher business stability, and supports the capability to grow the business like never before.  

Zero System Downtime. By design the Manufacturing process, the machine dependency, or what’s known as Bottleneck, within the system is eliminated. this means that if any of the individual machine is down for any reason, the production does NOT need to stop, in fact, the manufacturing process will continue running like it usual, while the individual machine is getting fixed or supported. without involving any special technologies, non-productive equipment, no extra infrastructure, the manufacturing system is available 100% of the times. 

As everyone was waiting for a substantial change in the manufacturing industry, We're Glad to Introduce over 30% savings in Real Estate, Capital Cost, Operational Cost, Maintenance, across the board. As we changed the problem itself, we have changed the mathematical relations among all The Manufacturing Process Parameters, which allows for a non-existing level of efficiency, That Allows for a smaller, Lower Cost, Robust, and the most productive manufacturing process.