Flexibility for navigating constant changes and intelligence for driving efficiency improvement
As a vital segment of the non-standard manufacturing sector, the liquid product packaging machinery industry is generally characterized by multi-variety, small-batch production. Coupled with such industry pain points as long manufacturing cycles, uneven order distribution and frequent changes in customer demands, traditional manufacturing models can no longer meet the requirements of high-quality development. Against this backdrop, Tech-Long seized the opportunity of its plant expansion and renovation project, with the core objectives of addressing industry pain points and leading industrial upgrading. In the planning of its new factory, it deeply integrated cutting-edge manufacturing concepts with intelligent technologies, striving to build a brand-new smart manufacturing system that integrates flexible production, efficient assembly, precise quality control, and intelligent logistics, sophisticated production scheduling and AI-enabled services. It injects strong impetus into the high-quality development of the packaging machinery industry through manufacturing model innovation.
Pioneer flexible production lines and reshape non-standard manufacturing processes.
Drawing on the flexible manufacturing philosophy of process-driven industries such as automotive in a groundbreaking manner, Tech-Long's new factory has taken the lead in applying flexible production lines to non-standard equipment manufacturing within China’s packaging machinery industry, disrupting traditional manufacturing models and pioneering a new industry paradigm.
In the future, the factory will carry out production in an orderly manner at a fixed takt time, realizing an innovative production mode of "machines move, workers stay put". Workers only need to complete standardized assembly procedures at their designated workstations without the need for frequent job switching. This model not only effectively addresses the adaptation challenges posed by multi-variety, small-batch production, but also significantly improves assembly efficiency and quality through standardized operations, while notably lowering the skill requirements for assembly workers. The company can adopt a targeted rapid training program for specific processes to efficiently meet the demand for skilled workers during production peaks, providing a replicable and scalable practical model for process optimization in the packaging machinery industry. Going forward, the company will integrate the flexible production assembly philosophy into the assembly process of all products, so as to comprehensively enhance the overall production efficiency of the enterprise.
Enhance quality control across the entire chain to lay a solid foundation for product quality.
Quality is the core competitiveness of an enterprise. The new factory will continue to implement the company’s established full-process and full-life-cycle quality management system, fostering a zero-defect quality culture featuring full staff participation and continuous improvement internally. Through the adoption of new quality management tools such as AI quality control assistants and inspection robots, as well as the investment in a ten-million-yuan flexible FAT (Factory Acceptance Test) production line, the factory will achieve accurate identification and closed-loop handling of quality risks across all stages, from design, core component procurement and production assembly to finished product delivery. This will significantly reduce rework costs and quality risks, further enhance equipment stability and reliability, meet the market’s quality requirements for packaging machinery products to higher standards, and help drastically shorten product delivery cycles.
Build a smart logistics system for automated warehousing and distribution.
To enhance production flow efficiency, the new factory has introduced an automated storage and retrieval system (AS/RS) and an intelligent warehousing system, paired with dedicated robots for material handling. These robots accurately identify the component requirements of each workstation and directly deliver the required materials to the corresponding workstations within the specified time, fully realizing an intelligent logistics mode of "materials coming to workers". Meanwhile, the production process flow of machining equipment across the entire factory area has been optimized, significantly improving the transfer efficiency of processed materials between procedures. This layout will drastically reduce material handling time, avoid the problem of material accumulation or shortage at workstations, and ensure the smooth connection of the production process.
Enhance smart information systems for meticulous control over production planning and scheduling.
Beyond the upgrade of hardware facilities, leveraging the company’s years of experience in informatization development, we will further renovate and upgrade the APS+MES system to build a refined and dynamic production scheduling and management system. Through the real-time integration and analysis of data such as order demands, production resources, process progress and equipment status, the system enables the scientific formulation, dynamic adjustment and precise execution of production plans. Whether it is the overall arrangement of multi-variety orders or the handling of emergencies such as unbalanced order volumes and design changes, the system can respond rapidly and optimize scheduling schemes, ensuring the efficient allocation of production resources, minimizing production waiting time, and comprehensively improving the factory’s overall production management and control capability as well as market response speed.
Roll out an AI-driven operation and maintenance framework to realize efficient after-sales service delivery.
While consolidating its manufacturing hardware strength, the company is simultaneously advancing the intelligent upgrading of its service segment. It is deeply integrating AI technology into the after-sales service domain to build a highly efficient and accurate fault diagnosis and after-sales service system.
Going forward, the company will establish an exclusive knowledge base covering equipment maintenance essentials, common fault points and corresponding solutions, and conduct in-depth training for the AI system based on this knowledge base to develop an intelligent Q&A platform with professional service capabilities. In the future, both external customers and internal service personnel can interact through the AI Q&A platform to quickly obtain solutions to common problems, which will significantly lower the threshold for problem-solving and reduce communication costs. This innovative model will not only improve the speed of after-sales response and service quality, but also help internal staff quickly master service skills, further strengthening Tech-Long’s service competitiveness and providing customers with high-quality support throughout the entire equipment life cycle.
Tech-Long's brand-new smart factory represents not only a leapfrog upgrade of the company’s own manufacturing capabilities, but also a valuable exploration and innovation for the development model of the non-standard manufacturing industry. Going forward, as various plans are gradually implemented, Tech-Long will leverage its core advantages including flexible production, rapid delivery, intelligent management and control, and lean management to continuously address industry pain points, steadily improve product quality and delivery efficiency. With the power of innovation, it will lead the packaging machinery industry towards high-quality and intelligent development, create greater value for global customers, and set a new benchmark for the high-quality development of the industry.