Los ntawm Inefficiency mus rau Kev Txawj Ntse: Yuav Ua Li Cas XINJUN Intelligent's Multi-head Weigher Hloov Kho Cov Khoom Noj Khoom Haus Puffed Enterprise
Hauv kev sib tw thoob ntiaj teb cov khoom noj txom ncauj ua lag luam, kev tsim khoom lag luam thiab cov khoom lag luam sib xws tau dhau los ua kev sib tw tseem ceeb tshaj li qhov kev hloov pauv tshiab. Lub tuam txhab A (lub npe npe), tus thawj coj khoom noj txom ncauj nrog 20 xyoo ntawm kev paub hauv East Asia, tshwj xeeb hauv peb cov khoom lag luam (qos yaj ywm chips, cw crackers, thiab mov puffs) npog 12 SKUs. Nws cov khoom tsim tawm txhua xyoo tau ntev stagnated ntawm 8,000 tons, daig hauv qhov teeb meem ntawm "tso zis ntau ntxiv yam tsis tau txais txiaj ntsig ntxiv" vim yog cov qauv tsim tawm dhau los. Thaum ntxov 2024, lub tuam txhab tig musGuangzhou Xinjun Intelligent Technology Co., Ltd.-ib txoj cai pioneering hauv Tuam Tshoj txoj kev lag luam tsis siv neeg qhov hnyav thiab ntim khoom lag luam- thiab qhia Xinjun's 16-lub taub hau tsis siv neeg qhov hnyav thiab ntim cov kab ntau lawm. Qhov kev sib koom tes zoo no tsis tsuas yog pab Tuam Txhab A ua tiav kev ua tau zoo, kev ua tau zoo, thiab muaj txiaj ntsig tab sis kuj ntxiv dag zog rau Xinjun Intelligent tus qauv ntsuas hauv cov khoom noj txom ncauj puffed automation sector.
I. Ua ntej- txhim kho Dilemma: Peb Lub Ncauj Ncauj Ncauj Ncauj Ncauj Ntau Lawm
Nrog peb cov kab ntau lawm, Lub Tuam Txhab A yav dhau los tau txais ib qho qauv tsim khoom: "manually faib khoom + ib leeg- taub hau hnyav + semi- tsis siv neeg sealing". Raws li ob lub siab ntawm kev xav tau ntawm kev lag luam thiab nce kev xav tau zoo, cov teeb meem pom tseeb tshwm sim:
• Efficiency Bottleneck:
Labor Dependence txwv tsis pub muaj peev xwmTxhua kab ntau lawm xav tau 6 tus neeg ua haujlwm rau kev faib khoom, kev pabcuam hnyav, thiab kev tshuaj xyuas kev sib khi. Qhov siab tshaj plaws ceev ntawm ib kab tsuas yog 25 pob ib feeb xwb. Kev cuam tshuam los ntawm tib neeg qaug zog, lub sijhawm ua haujlwm txhua hnub yog tsawg dua 10 teev. Thaum lub sij hawm 2023 lub caij ncov, qhov kev txiav txim xa mus txuas ntxiv mus rau 7-10 hnub, thiab lub tuam txhab pheej rov ua dua kev tshaj tawm kev koom tes nrog cov khw loj loj vim muaj peev xwm tsis txaus.
• Nqi Bottleneck:
Cov khoom siv khib nyiab siab thiab cov nqi ua haujlwmIb qho - lub taub hau hnyav muaj qhov hnyav hnyav (± 3% -± 5%). Txhawm rau kom tsis txhob muaj qhov tsis txaus siab, cov neeg ua haujlwm feem ntau txhob txwm tshaj tawm cov ntaub ntawv ntxiv - ua rau 120 tons ntawm cov khoom siv raw tsis tsim nyog rau cov qos yaj ywm chips ib leeg, nrog rau kev lag luam ncaj qha poob ntau tshaj $ 120,000 ib xyoos ib zaug. Lub caij no, tus nqi ua haujlwm txhua xyoo rau peb kab mus txog $ 324,000, suav txog 23% ntawm tag nrho cov nqi tsim khoom, deb tshaj qhov nruab nrab ntawm kev lag luam.
•Quality Bottleneck:
Instability Damaged Brand ReputationKev tuav tswj tau ua rau muaj kev hloov pauv loj hauv kev sib khi, ua rau 2.8% huab cua to thiab txee lub neej tsuas yog 3 lub hlis. Kev tsis txaus siab txog "qhov hnyav tsis txaus" suav txog 65% ntawm tag nrho cov kev tsis txaus siab. Hauv 2023 thib peb- tog zoo inspection, kevny qhov kev ntsuam xyuas tus neeg muag khoom raug txiav tawm vim qhov hnyav sib txawv, cuam tshuam rau nws txoj kev tsim nyog los koom tes nrog cov khw muag khoom yooj yim.
II. Breakthrough: Precision Selection Adapting to Puffed Snack Characteristics
Thaum kawg ntawm 2023, Tuam Txhab A tau tsim ib pab neeg txhim kho tshwj xeeb. Tom qab ntawm - qhov chaw tshuaj xyuas ntawm 12 cov tuam txhab cov khoom lag luam thiab 3 qhov kev sim ua qauv nruj, nws thaum kawg xaiv Xinjun Intelligent's 16- lub taub hau hnyav thiab ntim cov kab ntau lawm (nrog rau lub hnab ntsug- ua tshuab ntim tshuab thiab nitrogen flushing system). Qhov kev txiav txim siab tau tsav los ntawm Xinjun's 18-xyoo kev txawj ntse hauv kev lag luam khoom noj txom ncauj, ntau dua 5,000 qhov haujlwm ua tiav, thiab nws lub peev xwm los muab cov kev daws teeb meem customized raws li cov khoom noj txom ncauj 'fab fab, lub teeb yuag, thiab noo noo-absorbent' yam ntxwv. Cov ntsiab lus tseem ceeb ntawm kev sib koom tes yog raws li hauv qab no:
1. Ntsuas qhov system
Xinjun's Core Technology ntsuas qhov nrawm thiab qhov tseebXinjun's 16-lub taub hau hnyav, ua ke nrog tus kheej- tsim "kev sib xyaw ua ke ntse", ua tiav qhov hnyav ntau ntawm 5g-500g los ntawm kev sib koom ua haujlwm ntawm 16 siab- qhov tseeb qhov hnyav hoppers. Nws raug yoog mus rau ob qho tib si 20g me- pob cw crackers thiab 100g loj- pob qos yaj ywm chips, nrog rau kev ua yuam kev nruj me ntsis nyob rau hauv ± 0.8%- deb tshaj qhov kev lag luam nruab nrab ntawm ± 1.5%. Qhov no tsis tsuas yog ua tau raws li cov kev xav tau ntawm SKUs sib txawv tab sis kuj zam cov khoom siv rov ua dua. Lub caij no, cov zaub mov- qib 304 stainless hlau hnyav hoppers nrog Xinjun tus tshwj xeeb anti-stick Teflon txheej tag nrho daws cov teeb meem adhesion ntawm mov puffs, qhov mob ntev ntev hauv kev lag luam.
2. Pub Tsim
Customized Solution rau FragilityXinjun's R&D pab neeg kho kom haum peb -theem sib txawv zaus vibrating feeder rau tuam txhab A cov qos yaj ywm tawg. Los ntawm kev txo cov kev vibration zaus los ntawm 30% thiab ntxiv cov zaub mov- qib silica gel buffers nyob rau hauv cov zaub mov channel (ib tug Xinjun patented tsim), cov ntaub ntawv breakage tus nqi raug txo los ntawm 5% (ib txwm hom) mus rau 0.3%. Rau cw crackers nrog fluidity zoo, lub feeder siab - zaus vibration hom ua kom cov khoom tsis sib xws, nrog xoom blockage tshwm sim nyob rau hauv 24- teev tas mus li kev khiav hauj lwm-tsim cov khoom ruaj khov kev ua tau zoo.
3. Ntim Txuas
Integrated System Txhim khu kev ruaj ntseg zooXinjun cov kab ntau lawm ua ke sib xyaw ua ke dual-channel UV sterilization, siab -purity nitrogen flushing, thiab servo- tsav sealing tshuab. Lub tshuab nqus dej nitrogen tswj cov khoom seem ntawm cov pa hauv qab 1.2%, ncua lub txee lub neej ntawm 3 lub hlis mus rau 6 lub hlis. Lub servo-tsav sealing system, nrog rau qhov tiag -lub sij hawm kub thiab siab xyuas, xyuas kom meej sealing tus nqi ntawm 99.9%. Tsis tas li ntawd, qhov tsim -hauv AI qhov kev tshuaj xyuas qhov muag pom (co-tsim nrog Xinjun tus tswv cuab kev sib tw) tau txheeb xyuas qhov tsis xws luag xws li wrinkles thiab pa tawm, nrog rau 100% kev tsis lees paub rau cov khoom tsis tsim nyog. Thaum lub sijhawm sim ua haujlwm 3 lub hlis, tsis muaj kev tsis txaus siab txog kev ntim khoom tau txais.
4. Kev tswj ntse & Tom qab- muag
Kev them nyiaj yug puv -cycleCov cuab yeej tau nruab nrog Xinjun tus kheej -tsim PLC tswj qhov system thiab cov neeg siv- tus phooj ywg touchscreen interface, txhawb nqa qhov ntsuas qhov ntsuas rau 12 cov khoom thiab 30- thib ob SKU hloov. Nws txuas mus rau Tuam Txhab A's MES system, ua kom muaj tseeb - cov ntaub ntawv upload sijhawm thiab puv - txheej txheem digital traceability. Tshaj li cov khoom siv, Xinjun tau muab ib qho -nres kev pabcuam pob: 7-hnub kev teeb tsa ntawm qhov chaw, 15-hnub kev cob qhia tus neeg ua haujlwm, thiab 24/7 kev txhawb nqa (teb teb hauv 2 teev). Qhov kev pabcuam tag nrho no tau ua kom cov kab ntau lawm tau ua haujlwm ruaj khov hauv 1 lub hlis xwb, 50% sai dua li kev lag luam nruab nrab lub sijhawm debugging.
III. Txhim kho cov txiaj ntsig: Qhov "Multiplier Effect" ntawm Kev Muaj Peev Xwm thiab Nyiaj Tau Los
Cov kab ntau lawm tau raug muab tso rau hauv kev ua haujlwm hauv lub Peb Hlis 2024. Tom qab ib lub hlis ntawm kev ua haujlwm, nws tau mus txog lub xeev ruaj khov, nrog rau txhua qhov ntsuas tau ua tiav kev txhim kho leapfrog - tau cuam tshuam hauv "peb nce thiab peb txo":
| Qhov taw qhia hom | Ua ntej hloov kho (ib kab) | Tom qab hloov kho (Pib Kab) | Hloov tus nqi |
| Ntim ceev | 25 pob / min | 80 pob / min | +220% |
| Kev Tshaj Tawm Txhua Hnub | 3,2t ua | 9,6t ua | +200% |
| Yam Khoom Muaj Peev Xwm | 97.2% | 99.8% | +2.6 feem pua cov ntsiab lus |
| Tus Nqi Ua Haujlwm Txhua Xyoo | $108,000 | $27,000 | -75% |
| Cov khoom pov tseg tus nqi | 1.5% | 0.3% | -80% |
| Cov Neeg Siv Khoom Tsis Txaus Siab | 1.2% | 0.15% | -87.5% |
Los ntawm qhov kev xav tau nyiaj tau los, ib qho kev hloov kho ntau lawm ua rau cov khoom tsim tawm txhua xyoo los ntawm $ 1.8 lab, txuag $ 96,000 hauv cov khoom pov tseg, thiab txo cov nqi zog los ntawm $ 81,000. Cov cuab yeej siv peev (nrog rau kev teeb tsa thiab kev ua haujlwm) tau rov qab los hauv 14 lub hlis. Qhov tseem ceeb tshaj, nrog kev ruaj khov zoo thiab muaj peev xwm xa khoom sai, Lub Tuam Txhab A tau txais A- qib kev tsim nyog ntawm cov khw muag khoom yooj yim. Hauv thawj ib nrab xyoo 2024, kev txiav txim tshiab tau nce 45% xyoo-ntawm- xyoo, nkag mus rau East Tuam Tshoj ua lag luam.
IV. Case Insights: Core Logic of Automation Upgrade in Puffed Snack Industry
Company A's upgrade casemuab cov kev paub dhau los rau puffed khoom noj txom ncauj cov lag luam 'automation transformation. Lub ntsiab lus tseem ceeb yog:
Kev ntim khoom ntawm cov khoom noj txom ncauj puffed yuav tsum ua raws li ob lub hauv paus ntawm "ua kom haum rau cov yam ntxwv ntawm cov khoom siv + kev xav tau ntau lawm". Tus nqi ntawm ntau- lub taub hau hnyav cov khoom siv sib xyaw ua ke tsis yog nyob rau hauv "hloov kev ua haujlwm" tab sis kuj tseem ua kom tiav tag nrho - txheej txheem kev ua kom zoo dua los ntawm "precision hnyav + ntse txuas + kev tswj cov ntaub ntawv".
Nrog rau kev nkag mus ntawm Kev Lag Luam 4.0 thev naus laus zis, ntau - lub taub hau hnyav ntim cov khoom siv tau hloov zuj zus mus rau "ntau dua, kev txawj ntse, thiab kev siv hluav taws xob". Nyob rau hauv lub neej yav tom ntej, virtual commissioning thiab tej thaj chaw deb kev khiav hauj lwm thiab txij nkawm los ntawm cov ntxaib systems yuav coj ntau dua efficiency thiab kev ua lag luam kev sib tw rau puffed khoom noj txom ncauj qhauj.