The customer is a leading global connector manufacturer requiring MIJOINT's assistance to achieve high efficiency, superior quality, and exceptional stability for this product series, while realizing flexible production capabilities for rapid switching among different connectors within the series.
Through communication with the customer, this project represents a traditional high-speed connector product with wide applications and substantial market demand. The manufacturing process for this product series is relatively complex (including soldering, bending, pin insertion, IMD assembly, etc.), and product quality requirements are high. To meet the customer’s demands for “high efficiency, high quality, and high flexibility,” we optimized the process in the following directions:
1. Integrate “discrete processes” into “continuous flow production”;
2. Precision feeding system;
3. Utilized a high-precision intelligent assembly system combining cams with servo motors;
4. Integrate high-precision vision systems and performance testing instruments; achieve full-line computerized parameter control.
The manufacturing process for this product series is relatively complex (including soldering, bending, pin insertion, IMD assembly, etc.), and product quality requirements are high. Customers urgently need to resolve the pain-points including lengthy changeover cycles and unstable quality, to enhance return on investment (ROI) and ultimately achieve flexible production capabilities for quick changeover.
Discrete processes and 90% manual operations result in low capacity and unstable quality. When it is necessary to switch to other products with different part numbers for production, lengthy equipment changeover cycles lead to prolonged idle time. Extended changeover time severely delays delivery schedules and reduces return on investment. Besides, overdependence on technical personnel also drives up the overall costs.
Through further communication with the customer, we gained an in-depth understanding of their current product range, manufacturing processes, and existing equipment. Based on their needs, we developed a tailored solution for their factory. Our project implementation steps are as follows:
1. Establish design standards: First, we systematically standardized each assembly process to ensure high precision, high stability, and high flexibility.
2. Build a precision drive system: We utilized servo motors & cam-driven types to achieve high-speed and high-precision positioning within ±0.02 mm, laying the foundation for assembly.
3. Integrate intelligent inspection modules: We configured conductivity, dimensional, and appearance inspection functions, enabling one-click parameter switching and 100% defect removal.
4. Achieve modular program control: We designed independent, one-click callable program systems for each station, including feeding, assembly, inspection, and packaging, to achieve full-line integration.
|
Performance Indicator |
Before Improvement |
After Improvement |
Improvement Range/Effect |
|
Cycle Time (CT) |
6s/pcs |
3.5s/pcs |
CT reduced by 42%; hourly capacity increased by 71.4% (from 600 pcs/h to 1030 pcs/h) |
|
Changeover Time |
48 h |
8 h |
Changeover time reduced by 83.33%; equipment idle rate significantly decreased; order response speed increased by 8 times |
|
Labor Configuration per Shift |
13 HC/shift |
2 HC/shift |
11 HC saved per shift; labor cost reduced by 84.6%; management and training costs reduced |
