One line = 200 workers? Economics of Human Replacement in Air-conditioning Assembly Lines
A pragmatic automation path suitable for small and medium-sized manufacturers
- For most small and medium-sized air-conditioning companies, the fully automated solution of “replacing 200 people with one line” not only has huge investment, but also has difficult technical thresholds. But this does not mean that the status quo can only be maintained-through the combined strategy of “basic automation + semi-automation of key processes,” it is entirely possible to replace 200 workers with an air-conditioning assembly line, with controllable investment and lower risks.
- The core of this step-by-step transformation is: first solve the most labor-intensive links such as “handling, transfer, and repeated operations”, use a plate-chain conveying system to build the main production line, and then introduce semi-automatic equipment to replace some manual operations, and finally realize “Efficient collaboration model in which” equipment does heavy work and manual work is done cleverly.”
1.Stepped automation solution: A labor optimization path from basic transportation to semi-automation of key processes
- Parts porters: Plate chain conveying line + pneumatic pusher device is completely replaced, reducing the number of people by 15-20
- Product transfer workers: Automated conveying tracks are replaced, reducing the number of people by 8-12
- Screw tightening workers: Semi-automatic screw locking machine + manual assistance, reducing the number of people by 25-30
- Product packers: Semi-automatic baler + conveyor belt, reducing the number of people by 12-15
- Material sorting workers: material channel feeder + manual assistance, reducing the number of people by 10-15
2.Plate and chain conveying: the cornerstone of the automation transformation of air conditioning assembly lines
In the step-by-step automation transformation, the plate and chain conveying system is the most basic and critical investment. This kind of conveying equipment with metal chain plates as the bearing surface can stably convey heavy parts such as air conditioning casings and evaporators, and is a core solution to reduce handling manpower.
- Strong load-bearing capacity: A single chain plate can carry 50-100kg, suitable for air conditioner transportation
- Accurate positioning: Through chain pitch control, the workpiece parking error can be controlled within ±2mm
- Strong adaptability: can be designed into straight lines, turning, climbing, etc. to adapt to complex workshop layout
- Simple maintenance: metal link plates are wear-resistant and wear resistant, only need regular lubrication every day, and the failure rate is low
- The cost is moderate: the investment in a 100-meter-long plate chain line is about 150,000 – 250,000 yuan, which is much lower than the robot system
The “manual control + board chain conveying” mode can be adopted in the initial stage: the worker controls the start and stop of conveying through the foot switch, and then conveys it to the next step after completing the assembly. At this stage, 40-50 porters can be reduced, and photoelectric sensors can be gradually added to achieve automatic start and stop, reserving space for future upgrades.