How to Choose for Mass Production?

The choice of equipment has a direct effect on efficiency and cost.The results of these tests can be used to compare the processing speed, pass rates, and energy consumption of the two main types of processing equipment, and to help manufacturers choose the best option for their own needs.The contents of the book include an explanation of equipment parameters, a reproduction of the testing environment, and recommendations on selection.

Why is processing speed not the sole criterion?

When choosing equipment, many people's first reaction is to look at the "maximum processing speed" in the specifications table. This is actually a mistake.We have actually measured a certain brand of machine advertised to process 80 pieces per minute. But due to limitations on the feeding system and heat dissipation, it can only maintain a steady speed of 65 pieces per minute when running continuously.Here we recommend that you focus on two indicators: the stability of continuous operation (for example, the degree of speed fluctuation over an eight-hour period without stopping) and the yield rate (we have encountered a situation where the speed was up to standard but the defective rate soared to 30 %).

Two devices, two sets of data.

This time we borrowed two production lines from a factory and conducted a 72-hour comparative test using the same stainless steel parts.Before testing, the conditions were explained: the temperature in the testing room was 28 degrees plus or minus 2 degrees Celsius, and the humidity was kept between 50 % and 60 %, completely simulating the real working conditions of a hot southern summer.

Type A: Hydraulic.

- Average speed: 63 pieces per minute (75 pieces in the first two hours, then gradually decreasing).

- Electricity consumption: 18 % higher than the rated level. Engineers found a design defect in the lubrication system.

- Unexpected situation: At the 12th hour of the test, a paper jam occurred, and it took 47 minutes to get the machine back up and running.

Equipment B: New type servo motor driven.

Average processing speed: 71 pieces / minute (variance ± 2 pieces).

The egg-shaped device is equipped with a warning system that alerts the user 40 minutes before a bearing overheats.

Hidden costs: Need to upgrade voltage stabilization equipment, which increases initial investment by 15 %.

Three practical suggestions for selecting a type.

1. Don't be fooled by demonstrations in the showroom: Make the manufacturer bring the equipment to your factory to test it. We've learned from our own experience that the same equipment can perform very differently depending on the quality of the power supply.

2. Make sure you know what the hidden costs are. For example, although machine B is more expensive, it will have paid for itself in six months in terms of reduced waste.

3. Leave room for upgrading: The current order may not require smart networking, but if next year an order comes in for automobile components, a data interface will be necessary.

Finally, if the company is mainly doing small runs of many different products, I would suggest choosing a machine with a medium speed but a fast changeover time.The fastest of the machines took 45 minutes to change molds.