English (UK) 
简体中文 🧐Opening Soul Torture: does your conveyor line always lag?
"Why the same equipment, next door to the old king's family production is always higher than you 30%?"-Harm! Eighty percent of the conveyor line layout in dragging behind! Today, we will use 5 tactics to teach the novice white workshop to understand the whole, the efficiency of rubbing up! (Do not believe? (Do not believe it? An auto parts factory measured to save 18 yuan / minute downtime loss)
🔍Tip 1: X-ray the production line first.
Q: Where is the most effective place to start to optimise the layout?
Answer.Process analysis is the foundation!It's like you have to take a film to see a doctor, you have to feel it out:
- How long does each process take? Where do the workers squat to work?
- How does the material flow? Does it go round in circles on long distances?
To give you an example, a food factory found that the sauce canning station was 20 metres away from the packing line! That's a waste of 8 minutes/hour just for handling 👉.Optimised to cut out 60% invalid walks straight away!
📋Self-checklist (a must for the little guy!)
| analysis term | traditional method | Guide to avoiding the pit |
|---|---|---|
| Convergence of work processes | Drawing material movement routes with chalk | Eliminate cross and backflow (like untangling a mess!) |
| worker movement | Mobile phone video recording 1 hour of homework | Combining adjacent workstations to reduce turnaround |
| bottleneck positioning | Whoever has half-baked products piled up in front of them is the bottleneck! | Priority adjustment of congestion points |
📐Tip 2: Use the space like a game of Tetris!
Q: What can I do if the workshop is so crowded that I can't turn around?
Answer.Learn from the masters of storage, "put it up + walk against the wall"!
- U-shaped layout: The feeding and discharging ports are pasted together, and the workers stand in the inner circle 👉 It is not a dream for 1 person to manage 3 sets of equipments!
- Equipment spacing: leave an 80cm aisle (just enough to get a trolley through).Don't follow the example of a 4S shop with a luxury car!
👉 An electronics factory changed a straight line into a U-shape, saving 200 square metres of space to plug more production lines
💡Operation God.Put tall equipment against the wall (like a fridge against the wall) and short equipment in the middle - for a good view and easy access!
🤖Tip 3: Putting the "brain" in the conveyor line
Q: How do automation and people divide up the most flavourful work?
A: Let the machines do the grunt work and the people manage the decisions!
- primerAdd photoelectric sensors to the conveyor line, automatic stopping of clogged materials, avoiding the pile of mountains and then fumbling.
- advanced version: AGV cart + RFID chip (on material).Real-time tracking of where every box is.
👉 A chemical plant used this trick to find goods from 15 minutes → 30 seconds
⚠️Attention.Don't drop money on robots right off the bat! Give the old equipment first.Installation of inverters-Adjustable speed and lower electricity bill 25%
🛣️Tip 4: Straighten out the "nine bends and eighteen twists"!
Q: How much of an impact does a conveyor line with lots of turns have?
Answer.For each additional turn, the efficiency drops 5%.Friction resistance + collision loss is not to scare you.
Optimising the triple axe.
- the straight line is king: Learn from the underground to fix a straight track and use less S-shaped windy walks
- Obtuse cornering: Hard to make a turn? Angle ≥ 120° (like a motorway ramp)
- crash cushion: Rubber strips on turns, clunks become muffled 👉 Parts breakage rate dropped by 70%
📏The Golden Formula.For every 1 metre shortening of the transmission distance, the annual saving in electricity costs is ≈200 yuan (calculated on the basis of 10 hours/day)
⚖️Tip 5: Don't let the conveyor line "pick up the slack."
Q: Why do I always skid/run?
A: Overloading and bias loading are the culprits!Remember this set of numbers:
- Single point load ≤ design value 80%(500kg line up to 400kg)
- centre a weightThe lightweight objects are divided into two sides 👉 Like riding a bicycle with a cargo basket!
🛠️Emergency juggling: Sudden slippage in production?
- Sprinkle rosin powder to increase friction (remember to wipe it off with paraffin afterwards!)
- Frequency inverter lowers speed to 50% to maintain production.
- Check drive wheel tooth thickness immediately👉 Wear over 3mm must be replaced!
📅Exclusive long-lasting crash prevention schedule
| cyclicality | Key actions | Cost/time | return rate |
|---|---|---|---|
| (soup etc) of the day | Hoover to clear chain seams | $0/10min | Risk of jamming ↓70% |
| every month | Laser calibration guide (<0.5mm/m) | 500 per session | No need to change the chain for three years |
| quarterly | Running a new layout with simulation software | Software leasing | Anticipate bottlenecks |
Personal Violence Theory.Don't believe that "the more expensive the equipment, the better"! I've seen too many factories spend millions on new lines.The layout is like a stall.--Actually, chalking up analogue lines + used sensors would squeeze out the 30% potential! After all, shop efficiency = layout IQ x equipment diligence, don't you think? 😉
