Multi-species small batch precision parts processing difficult? Flexible automated production line to break the game

In the field of precision manufacturing, the demand for multi-species and small-lot orders is becoming a mainstream trend, and companies in the aerospace industry, precision mould industry, medical equipment and other industries are suffering from a series of pain points and moving forward: trial and error in R&D, time-consuming and laborious production changeover, lack of quality stability, and high hidden costs. ...... traditional production line in the flexibility and efficiency of the balance between the difficult to move forward, how to break the game into the industry's common problems. Flexible automated production line appears, is to provide the best solution to this predicament, mould treasure as a precision manufacturing digital factory solutions provider, but also with targeted technology to solidify the foundation of the breakthrough.

Pain Point Direct: The Four Core Dilemmas of Multi-variety and Small-lot Processing

Nowadays, those discrete precision parts processing enterprises, generally are faced with four major problems, and these four major problems have become the bottleneck of its development constraints.

Firstly, there is a gap between R&D and trial production that is difficult to cross, even if the engineer's CAD design is extremely sophisticated, however, in the face of complex 3D models, alien structures and strict tolerance requirements, it is often difficult to be successfully transformed into qualified physical prototypes, and if the process is not selected appropriately, it is easy to lead to deformation of the parts, the performance is not up to the standard, and repeated trial and error not only slows down the pace of innovation, but also increases the cost of research and development.

Secondly, the low efficiency of production change on the formation of capacity constraints, small batch and multi-variety orders, which indicates that from time to time to change the production of traditional special equipment, adjusting fixtures, moulds, and procedures, need to spend hours, or even days, the utilization rate of the equipment has been significantly reduced, it is difficult to take into account the speed of response to the order and production efficiency at the same time.

In addition, there is pressure on quality and cost. Manual processing is affected by a variety of factors, such as differences in skills and fatigue, and it is difficult to maintain its accuracy at the micron level, resulting in a consistently high defective rate; at the same time, the losses caused by downtime due to unqualified parts, as well as delivery delays and thus triggered by the cost of breach of contract and other hidden costs, which further increases the overall cost of the company. The

Fourth, production control is quite obvious that there is a lack of transparency of the situation, the information between the various links presents a situation of mutual fragmentation, production data can not do real-time collection, quality problems are difficult to accurately trace, the state of the equipment operation can not be effectively monitored, the lack of data to give support to management decision-making.

The key to breakthrough: the core advantage of flexible automated production lines

Flexible automation production line to the traditional automation is only suitable for mass production limitations to break, with “flexible adaptation, accurate and efficient, intelligent control” features, for the industry to crack the pain points, its core advantages in three dimensions:

Quick response, efficiently adapting to the needs of multiple varieties. Relying on modular design and intelligent programming technology, the flexible production line can carry out rapid switching of machining categories, and the production changeover time is significantly reduced compared to traditional production lines. Modalbao Flexible Manufacturing Automation System (FMS) software, as the key to the core of industrial control that demonstrates the characteristics of self-control in China, is able to achieve the automatic matching of multi-species parts, automatic transport of materials and loading and unloading, etc., and cooperate with the rapid clamping technology to promote the efficiency of production changeover of more than 60%, and to effectively achieve the efficient and smooth operation of the production of single-piece, multi-species mixed production lines.

Precision and stability are the cornerstones of quality control. Automated equipment can maintain the machining accuracy within ±0.01mm for a long period of time, thus avoiding the uncertainty of manual operation and controlling the defective rate at a very low level. The CNC flexible automated machining unit and CMM automated inspection unit built by Modalbao finally form the automated closed loop of the whole process of “machining - inspection”, combined with the ability of production data visualisation and process transparency, real-time data collection of cutting parameters, tool wear, etc., to achieve accurate traceability of quality problems. It can achieve accurate traceability of quality problems and guarantee the consistency of parts from the source.

In the process of achieving the goal of reducing costs and increasing efficiency, full-cycle value optimisation is achieved. Flexible automated production lines reduce the reliance on skilled labour, improve equipment utilisation and reduce scrap rates, resulting in a significant reduction in overall costs. Modebao intelligent robot CCR integrates the system, the material frame and the robotic arm into a single unit, with a small footprint, low cost, fast implementation speed, and the ability to achieve unmanned production 24 hours a day, which not only greatly improves the work efficiency, but also controls the manpower cost and the energy cost within a reasonable range, and helps the enterprise to calculate the “whole life cycle cost” big account. help enterprises to calculate the "whole life cycle cost" of the big account.

Modulo Empowerment: Full Scenario Solutions from Cell to Production Line

As a solution service provider focusing on the discrete manufacturing industry that many different varieties, small batch production of precision parts machining work on the point of view, Diebold by virtue of the “integration of hardware and software, the edge of the cloud synergy” as the core point, to create a combination of flexible automation ecological environment covering all process links. Whether it is EDM flexible automated machining cells, flexible automated hybrid machining lines, or customised solutions for aerospace, precision moulds and other specialised fields, they can all accurately match the needs of enterprises.

Modalbay's flexible automated production line is not just a simple integration of equipment and software, it can also achieve production optimisation, comprehensive monitoring and horizontal collaboration between the depth of integration, this integration can break down departmental information barriers, can enhance the ability of cross-process co-ordination, to help enterprises to achieve the ultimate goal of lean production and the “lights out factory”. Starting from improving equipment efficiency and stabilising manufacturing quality, all the way to reducing manpower costs and accelerating order delivery, Modalbay is promoting precision manufacturing enterprises to break through the development bottleneck with practical technical solutions.

On the multi-species small batch precision parts processing pain points, it is never the kind of problem that can not be solved, but is an opportunity for industrial upgrading. If you choose Moldbauer flexible automated production line, with intelligent technology to replace the original reliance on traditional methods, through flexible adaptation to cope with changes in the market, so that the processing problems encountered will not become a hindrance to the development of the constraints, so that you can comfortably grasp the new opportunities brought about by high-end manufacturing!