English (UK) 
简体中文 Why are factory conveyor lines always "burning out"?Many companies purchasing conveyor lines, only focusing on the price of equipment but ignoring the hidden costs, resulting in late maintenance fees skyrocketed, downtime losses doubled. The following set of methodology, can make the selection of efficiency 50%, the comprehensive cost straight down 25%.
Step 1: Pinpoint your needs and avoid "over-consumption"
The central question: how to meet the immediate needs of production at the lowest cost?
Reverse derivation of equipment parameters based on material characteristics is the key to controlling costs:
- List of Material Characteristics
- Shape/Size: Roller line for regular boxes (space-saving), belt line for bulk pellets (spillage prevention)
- weight limit: >50kg material must use chain plate line (ordinary belt is easy to break)
- special propertyFood & Pharmaceuticals: Stainless steel (anticorrosive), electronic components with anti-static design.
- Environmental adaptation formula
Abandonment of plastic components in high-temperature workshops (risk of deformation), addition of sealed covers in dusty environments (reduction of failure rates) - Budgetary cuts
Used roller line retrofit cost lower than new 40% (need to check the core drive components), non-critical areas with powerless rollers to reduce consumption 30%
Case: an electronic factory conveying mobile phone screen, the original cost of 280,000 chain line. Later changed toFlexible anti-scratch belt lineThe material is only 0.5kg/chip, the cost is only $150,000 after transformation and the breakage rate is zero.
Step 2: Match the device type to reject "wasted performance"
The central question: Which features are purely "invalid mark-ups"?
Avoid allocation traps against this decision table:
| Production Line Requirements | Cost-effective programme | The Premium Trap |
|---|---|---|
| <10 metres short distance conveyance | Powerless roller line (zero energy consumption) | Automatic sorting system (3 times more expensive) |
| Changing direction/climbing | Modular webbing (can be disassembled and reassembled) | Custom curved track (duration + 15 days) |
| Accuracy ±1mm positioning | Servo motor + encoder | Full robotic guidance (overdemand) |
lesson learnt through blood and tears: An auto parts factory selects a 20kg part for theSpeed Chain Line, which actually carries only 30%, but spends an extra $120,000 to strengthen the structure - a sum large enough to retrofit 2 QCs.
Step 3: Cost dynamic control, squeeze every cent of the budget.
The central question: how to get suppliers to voluntarily reduce prices?
Master these 3 tricks of negotiating leverage:
- energy-consumption ratio pricing method
Requires disclosure of no-load/full-load power consumption (e.g. 1.5kW motor saves ￥8000+ per annum compared to 2.2kW) - Modular Sourcing Strategy
Core drive parts imported (SEW/Siemens), bracket/guardrail choose domestic (price difference 50%) - Maintenance betting agreement
Signing of the "compensation for faulty downtime" clause (example: ￥2000 for 1 hour of downtime)
Industry Data.Maintenance costs as a percentage of equipment life cycle investment 35%--Select a conveyor line with quick-release structure and reduce the time to change rollers from 2 hours to 15 minutes.
Final Decision MantraLightweight materials are belted, heavy goods are chained, mesh belts are used for turning, and short-pitch rollers are sufficient. When the supplier recommends the "top solution", please read it silently.All the extra features are money that will be wasted tomorrow.
(A daily chemical company used this model to select a line, the initial investment dropped by 180,000 yuan, 3 years of comprehensive operation and maintenance costs saved 420,000 yuan - enough to build another packaging line)
