The automation transformation of plastic modification production lines can usually achieve a comprehensive production efficiency improvement of 30% to 60%
1, Contribution to the improvement of core efficiency: (1) Ingredient process: manual batching with a single batch operation time of ≥ 15 minutes and an error of ≥ 5%; The single batch time of the automatic weight loss scale/volumetric batching system is ≤ 3 minutes, with an error of ≤ 0.2%. The efficiency of this process has been improved by more than 300%, which is the core driving factor for overall improvement. (2) The mixing process: automatic temperature control closed-loop adjustment, eliminating temperature drift deviation caused by manual operation, improving mixing stability, indirectly reducing the defect rate by 8%~12%, corresponding to an effective production capacity increase of 8%~15%. Key conditions affecting the extent of improvement
The foundation of the original production line: the transformation of the fully manual production line (adding ingredients and central control system) has increased by 50% to 60%; The transformation and improvement of the semi-automatic production line (only automatic after mixing) has increased by about 30% to 40%
Process matching degree: The modification needs to be adapted to the characteristics of the modified formula (such as the precision requirements of the glass fiber reinforcement material ingredients and the temperature control requirements of the fuel resistance). If the matching degree is low, the improvement rate will be reduced by 10% to 15%
Personnel adaptation: The rated increase can only be achieved after completing the training on operating the automation system; The initial improvement rate of unsuitability is ≤ 20%, and after proficiency, it returns to the interval range. III. Boundary limitations of efficiency improvement: (1) Due to the physical limitations of the mixing process, automation transformation cannot break through the theoretical upper limit of the hourly production capacity of a single line (such as the theoretical hourly production capacity of a twin-screw modification line is 2 tons, and the maximum effective production capacity after transformation is about 1.6 tons, which is 80% of the theoretical value). (2) Efficiency improvement specifically refers to the output of qualified modified materials per unit time, and does not include non capacity implicit values (such as labor cost reduction and defect rate reduction). Implicit values are not included in the statistical interval of core efficiency improvement
