How does the LED TV assembly line rewrite industry rules?
1.Welding in 5 seconds: A list of affordable automation equipment for small and medium-sized factories
There is no need to pursue the limit speed of “one unit per second.” For small and medium-sized factories,”completing one process in 5 seconds” is more than three times higher than the labor efficiency, and the equipment cost can be controlled at 100,000 – 300,000 yuan per unit, far lower than high-end equipment.
The core idea is to replace the “labor-heavy, high-repetition, and low-precision” process with automation, and still retain manual labor for complex testing and fine-tuning, which not only controls costs but also ensures quality.
“We will not recommend customers to buy million-level precision robots at the beginning, but use 2-3 basic automation equipment based on production capacity needs to solve the most labor-consuming links first. ”
2. Automatic equipment necessary for small and medium-sized factories
- Investment in glass substrates: Semi-automatic feeder + manually assisted positioning to avoid bumps (efficiency is increased by 1.5 times)
- LED chip packaging: basic die bonder (error ±0.05mm)+ manual re-inspection, the pass rate reaches 99.2%
- Circuit welding: Entry-level welding robot, 5 seconds per solder joint, replacing 3 skilled workers
- Complete machine testing and packaging: Semi-automatic test bench + manual random inspection, automatic packaging of qualified products (efficiency increased by 2 times)
3. Upgrade the LED TV assembly line in 3 steps
- Welding process: Welding is the “most labor-intensive, most repetitive, and largest manual error” process in LED TV production. A welding robot worth 150,000 yuan can replace 3 skilled workers (monthly salary of 8000 yuan), saving annual labor costs of 288,000 yuan., you can pay back the capital in 5 months.
- Transportation process: Material handling between processes may seem simple, but in fact accounts for 20-30% of the total manpower and is prone to bump and damage (defective rate accounts for 15%). The double-speed chain conveyor line can replace 2-3 porters while reducing material loss.
- Testing process: Manual testing efficiency is low (50 units per person per hour) and missed detection rate is high (about 8%). Entry-level visual testing machines can increase the detection efficiency to 200 units per hour, and the missed detection rate is reduced to 1%.
