Caso compartido: Una conocida empresa de materiales nuevos introdujo una máquina cortadora de película inteligente para lograr un aumento del 30% en la eficiencia de producción.

1. Project background: the joy of growth and the pain of transformation

The company is a leading manufacturer of functional film materials in China, and its products are widely used in consumer electronics, new energy vehicles, high-end packaging and other fields. With the explosive growth of market demand, the company faces two core challenges:

1. Capacity bottleneck: The original old-fashioned slitting machine is inefficient, slow, and takes too long to change orders, which has become an obvious bottleneck in downstream production.

2. Quality fluctuations: High-end customers have extremely strict requirements for the slitting quality of film (such as burrs, winding neatness, tension control), traditional equipment relies on the experience of masters, quality stability is difficult to guarantee, and the risk of customer complaints is high.

3. Cost pressure: Labor costs continue to rise, and skilled operators are difficult to recruit and retain; The old equipment has high energy consumption and large material loss, which invisibly eats up profits.

In the face of these challenges, the company's management decided to invest in the introduction of advanced intelligent film slitting machines to create a digital and automated core production link.

2. Solution: Select and deploy an intelligent slitting system

After multiple investigations and rigorous evaluations, the company finally chose to cooperate with an internationally renowned equipment manufacturer to introduce its flagship intelligent slitting machine solution. The core advantages of this solution are:

• Intelligent control system: Equipped with an intelligent control system based on AI algorithms, it can automatically optimize slitting parameters (such as tension, speed, pressure).

• Fully automatic order change process: equipped with automatic loading and unloading tool system, automatic width positioning (AGV), online defect detection (CCD vision system) and other functions to achieve "one-click order change".

• Digital management platform: The equipment integrates MES (Manufacturing Execution System), which can monitor equipment status, production efficiency, and quality data in real time, achieving transparency and data-driven decision-making in the production process.

• High-precision mechanical structure: Adopts a highly rigid frame and precision servo drive to ensure stability and slitting accuracy in high-speed operation.

The deployment process is not all smooth sailing, and key steps include:

1. Pre-planning: Communicate deeply with suppliers to clarify all technical details and capacity targets.

2. Infrastructure renovation: Upgrade the infrastructure such as the plant floor, power, and gas sources to meet the requirements of new equipment.

3. Installation and commissioning: The supplier's team of engineers was installed in the factory and underwent precision commissioning for several weeks.

4. Personnel training: This is the key to success. Organize operators and maintenance engineers to conduct systematic training, from equipment operation, programming to basic maintenance, to ensure that the team can "control" rather than "depend" on new equipment.

3. Effectiveness analysis: a double leap between quantification and qualitative change

After the intelligent slitting machine was officially put into production, the effect was immediate, and the value continued to be released in the coming months:

1. Increase production efficiency by more than 30%:

◦ Slitting speed increased: The maximum slitting speed has been increased from 400m/min to 600m/min.

◦ Significantly shortened order change time: Traditional order change requires stopping to adjust the tool, width, etc., which takes about 30-45 minutes. The intelligent slitting machine realizes fully automatic adjustment, shortens the order change time to less than 5 minutes, and improves efficiency by more than 80%. This is the most important contribution point to the overall efficiency increase of 30%.

2. Significant Improvement in Product Quality:

◦ Product optimization rate improvement: intelligent tension control and online defect detection system reduce scratches, streaks, burrs and other problems during the slitting process by more than 70%, and the product quality rate is increased from 92% to 98.5%.

◦ Excellent consistency: Eliminates human operation differences, and the product quality is highly consistent in different batches and shifts, which greatly improves customer satisfaction.

3. Effective Reduction of Operating Costs:

◦ Labor cost savings: The number of operators required for a single production line has been reduced from 3 to 1 (mainly responsible for monitoring and loading and unloading), and labor costs have been significantly reduced.

◦ Reduced material loss: Precise cutting and stable winding reduce the generation of trimming and waste coils, and increase material utilization by about 2%.

◦ Reduced energy consumption: The servo motors and intelligent energy management system of the new equipment save about 15% of energy compared to the old equipment.

4. Digital management empowerment:

◦ Through the MES system, managers can view the OEE (overall equipment efficiency), order progress, and energy consumption of each equipment in real time in the office, realizing accurate data-based management and scheduling, and providing the possibility of continuous optimization.

4. Experience summary and enlightenment

The successful transformation of the enterprise has provided valuable practical experience for the intelligent upgrading of traditional manufacturing industries:

1. Top-level design is key: Intelligent upgrades are not simple equipment replacements, but systematic engineering involving production processes, management models, and personnel skills. It is necessary to plan from a strategic perspective and clarify objectives.

2. Choose the right partner: The supplier's technical strength, industry experience, and after-sales service are crucial. A partner who can provide a total solution rather than just selling equipment is the guarantee of project success.

3. "People" are the core element: No matter how intelligent the equipment is, it needs people to operate and maintain. Advance, adequate and in-depth personnel training is the core to ensure return on investment and avoid "low-end use of high-end equipment". It is necessary to pay attention to the training of technical teams and stimulate the enthusiasm of employees to embrace change.

4. Data is the future wealth: The vast amount of data generated by smart devices is a valuable asset. Enterprises need to establish the awareness and ability to utilize this data, continuously discover improvement points through data analysis, and achieve continuous lean production and intelligent iteration.

Conclusión:

By introducing intelligent film slitting machines, this well-known company not only solves the current production capacity and quality pain points, but also lays a solid foundation for the future high-quality development of the enterprise. This 30% efficiency improvement is a vivid epitome of intelligent manufacturing empowering the transformation and upgrading of traditional industries, proving that driving operational upgrading with technological innovation is the only way for manufacturing enterprises to maintain their core competitiveness in the fierce market competition.