Leading domestic plating company has partnered with MIJOINT to automate their processes, thereby enhancing efficiency, and yield and reducing labor costs. Please refer to the following case study for details.
The process flow of this project includes: plating rack dimension inspection, rack plating, plating process-1, flipping-1, dispensing, baking, flipping-2, plating process-2, flipping 3, plated product unloading, glue stripping, glue residue inspection, placing product onto cleaning tray, cleaning, and packaging.
Traditional equipment requires manual rack plating, resulting in low efficiency and yield and the inability to handle miniature products. Additionally, it was difficult to achieve precise rack plating/plated product unloading for products with 0.3 mm irregularly shaped plating holes and high-precision dispensing for irregularly shaped products.
Traditional equipment features low efficiency and insufficient precision, leading to high production costs and delayed deliveries. It fails to meet market demands for small-sized and irregularly shaped parts, directly undermining the customer’s order-taking capability and customer satisfaction. This will impair market competitiveness and profit margins in the long run.
The customer and MIJOINT team held meetings and investigated the factory's current equipment, product situation, and existing process flow. Then we formulated the following solution:
1. Upon receiving the project, we investigated the plating process with the customer. Through discussions, we finalized the rack plating process and preliminarily determined the structure of the plating racks and plating baskets.
2. After designing the plating rack, making samples, conducting DOE verification, and performing multiple rounds of verification on the structure and dimensions of the plating rack and Finite Element Analysis (FEA), we finalized the structure and dimensions of the plating rack.
3. Based on anti-corrosion requirements of the plating rack, we sourced suppliers for surface treatment, determined the material and thickness of surface plating, optimized plating uniformity, and conducted anti-corrosion and lifespan testing by immersing the plating rack in plating solution.
4. We conducted Failure Mode and Effects Analysis (FMEA) on the machine and DOE verification on individual verification modules (e.g., product rack plating verification, glue stripping verification).
5. We conducted 3D design, followed by primary and secondary design reviews, and then proceeded with 2D design.
6. Procurement, assembly, software & program installation, equipment debugging, and equipment MBO.
7. EVT, DVT, RAMP, and MP phase.
|
Performance Indicator |
Before Improvement |
After Improvement |
Improvement Range/Effect |
|
Daily Capacity |
2 kpcs/day |
55 kpcs/day |
Capacity increased by 2650%, meeting large-scale batch production demands |
|
Product Yield |
95% |
99.8% |
Yield increased by 5.05%, defective product cost reduced by 91.9% (estimated proportionally) |
|
Labor Configuration per Shift |
15 HC/shift |
3 HC/shift |
12 HC saved per shift, labor cost reduced by 80% |
