To meet the quick changeover demands of the top connector manufacturer in the world, MIJOINT offers flexible production solutions. Please refer to the following case study for details.
The process flow includes: Carrier inflow, simultaneous positioning of the carrier & steel sheet, sucking the steel sheet, placing the steel sheet onto the positioning pin plate, sucking the product from the tray, placing the product above the steel sheet, product & tape bonding, sucking the steel sheet & product to place them onto the carrier, and carrier outflow.
The traditional “one machine, one product” model cannot adapt to the production needs of multiple product varieties and fast iteration. The customer urgently needed to have it upgraded to quick changeover model to reduce costs, increase rate of return, thereby achieving flexible production.
The traditional “one machine, one product” model features inefficient changeover and low yield. Besides, equipment cannot be shared among multiple products, resulting in low productivity, high costs, and prolonged payback period.
After gaining an in-depth understanding of the customer’s products, processes, and equipment status, we developed a customized solution. The specific implementation steps are as follows:
1. Following the process from detailed communication with customer, risk assessment, provision of requirements & design report, 3D design with review, final confirmation with customer, 2D drawing annotation, parts subcontracting & machining, the manufacturing phase commences.
2. To address the pain-points of wide variety and frequent changeovers for the Flex product, we adopted a solution of “retain standardized machine + change non-standard parts for quick changeovers”. The standardization encompasses external structure, positioning methods, control systems, and related programs.
3. By standardizing the main structure of the equipment and optimizing the high-precision pin plate positioning system for different products, we’ve realized quick changeovers among all Flex series products and stable pickup/placement of multiple pieces of products.
4. We utilize the most advanced machining equipment to machine parts to achieve the production goals of high versatility and stability.
|
Performance Indicator |
Before Improvement |
After Improvement |
Improvement Range/Effect |
|
Cycle Time (CT) |
26s/pcs |
20s/pcs |
Cycle time shortened by 23.1%; hourly capacity increased by 30% (from 138 pcs/h to 180 pcs/h) |
|
Changeover Time |
4 h |
0.5 h |
Changeover time reduced by 87.5%; equipment shutdown loss for the production line reduced by over 90% |
