Automation transformation can improve the overall efficiency of reflow soldering production lines by 30% -50%, with the core being the elimination of manual operation bottlenecks, reduction of quality loss, and unplanned downtime.
1, Specific manifestations of efficiency improvement
(1) Beat compression
The original manual loading and unloading, tooling switching, quality inspection and other processes accounted for 15% -25% of the total production line cycle time. After automation replacement, the single cycle cycle cycle time was shortened by 20% -30%;
The repair rate caused by manual misjudgment has decreased from 3% -8% to below 0.5%, avoiding time loss due to production line downtime caused by rework.
(2) Continuous running time increase
Manual shift changes, rest breaks, and intermittent pauses account for 8% -12% of the original production line's operating time. After the transformation, it can achieve continuous operation for 22-24 hours (with supporting equipment on duty), and the annual effective operating time can be increased by 10% -15%.
2, Core influencing conditions for the increase in magnitude
(1) Original production line foundation
After the transformation of the semi-automatic production line (only the core heating area is automated), the improvement rate can reach 40% -50%; After the transformation of the fully manual production line (including manual operation of surrounding processes), it has increased by 30% -35%.
(2) Product type matching
Multiple varieties of small batch products, adopting flexible automation transformation with quick changeover function, with a 5% -10% increase in improvement compared to fixed products.
3, Key requirements for landing
(1) Equipment selection matching
Equipped with an automatic loading and unloading machine with visual positioning, a quick changeover fixture, and a temperature control module for butt welding to achieve automatic parameter calling.
(2) Security compliance control
The automation area needs to be equipped with protective gratings and emergency stop interlock devices, which comply with GB 28526-2012 "Safety Requirements for Welding Machinery". It is prohibited to modify the safety interlock logic in violation of regulations.
