Moving towards a 'new' direction with automated production lines to assist enterprises in improving quality and efficiency

Against the backdrop of the country's vigorous promotion of intelligent manufacturing, introducing automated production modes and promoting digital construction are the necessary paths for enterprise transformation. In recent years, Wanshengren and the molding department have focused on innovation driven development, systematically upgrading and optimizing the production equipment and process flow of medical device production lines, further improving the level of production and manufacturing, increasing investment in production line automation, and helping enterprises improve quality and efficiency.
New mold structure, technological breakthroughs to reduce costs
Since its establishment, the molding department has vigorously promoted the concept of technological innovation management and focused on the mass and rapid production of medical device accessories. By sorting and analyzing production processes one by one, comparing production data, targeting production bottlenecks and inefficient links, and continuously optimizing production processes.
Taking oxygen tube products as an example, it was found that the accessories produced in the injection molding process have problems such as burrs and bottle core deviation, which in turn require manual secondary processing before entering the next process. In order to improve production efficiency, the molding technology team has repeatedly studied and decided to start with the mold structure, adding a needle valve hot runner to the humidification umbrella and a cylinder to the bottle cap mold, effectively eliminating burrs. At the same time, utilizing independent innovation correction technology, the problem of bottle mold core deviation has been solved. After continuous testing and optimization, the injection molding process has reduced tedious steps such as manual processing and inspection, and the personnel configuration has been readjusted; The products produced also achieved a one-time standard, successfully shortening the production cycle and effectively reducing the total production cost. This innovative measure marks a solid step forward for the production workshop on the journey of automated production.
New manufacturing process, continuous optimization to improve efficiency
Standardization is the foundation of automation. To achieve automation in the production workshop, the molding department should first standardize the process and workflow, comprehensively review and evaluate the production process, conduct extensive basic data research, and develop standard process operation procedures to ensure consistency and controllability of the production process.
Based on process innovation, the molding department has also taken various innovative measures in equipment upgrading, changing the workshop cooling circulating water system to a centralized refrigeration cycle, significantly improving cooling efficiency and reducing equipment downtime; Optimize the assembly fixture structure to further improve production efficiency; At the same time, the development of new extraction fixtures, improvement of mechanical arm fixtures, reduction of semi-automatic operation processes, introduction of color masterbatch machines, central feeding systems and other series of automated equipment have achieved automatic batching, automatic conveying and other technologies in the workshop, greatly reducing the dependence on operators and improving overall production efficiency by 20%.
New production equipment, independent research and development to promote production
Automated production lines can introduce intelligent detection equipment to achieve quality control of products, reduce manual intervention, and improve product quality stability. However, due to the shape characteristics and semi transparent materials of the company's products, the existing equipment on the market often fails to meet quality inspection requirements, or the equipment prices are too high. Faced with difficulties, the molding department and the research and development department jointly established a project team in early 2024 to independently research and manufacture visual inspection equipment.
The project team members fully utilized their respective strengths, worked collaboratively, and successfully assembled the testing prototype by analyzing production principles, software algorithms, mechanical structures, and other aspects. After countless rounds of debugging and optimization, the problems of unclear shooting pixels and uneven light sources were gradually solved, ultimately improving the performance of the equipment. At present, the prototype has entered the overall testing stage and is expected to be officially put into use in the second half of the year. The production cost of the equipment is only over 10000 yuan, which saves more than 1.6 million yuan compared to devices with similar functions on the market. Based on the company's needs and production reality, the molding department has completed multiple technological improvements and innovations in the form of a project team, such as the transformation of automatic box changing equipment and the production of automatic assembly machines for water guide cores, laying a strong technical foundation for the sustainable development path of the enterprise with high efficiency and low consumption.
The advancement of automation not only conforms to the current trend of manufacturing transformation and upgrading, but also becomes an important means to improve the competitiveness of enterprises. In the next stage, the molding department team will continue to strengthen relevant technical research and training, continuously promote technological and management innovation, to adapt to the needs and challenges of the digital age, and promote high-quality development of the enterprise.