As an old technician who has worked in our factory for more than ten years, I am often asked by customers: "What is the difference between your packaging machines?" To be honest, what makes me most proud is not how bright the equipment parameters are, but that every step of our process from disassembly to assembly is as steady as "building blocks". Today, let's talk to everyone about the hard work hidden in the details of our factory.
1. Dismantle the old as new, the process is the basic skill
When it comes to the packaging machine disassembly process, many people think it is nothing more than screwing screws and removing parts. But do you know? Our factory has polished this link alone hundreds of times. For example, when an old device that has been used for three to five years is returned to the factory for upgrading, our master will first "scan the whole body" of the machine - from the wear of the transmission shaft to the aging of the circuit board, each part must be recorded. Why is it so serious? Because only by understanding the basics can we accurately determine which parts can be reused and which must be replaced.
Over the years, we have summarized a set of "three-step disassembly methods": first remove the outer guard plate, then remove the core components by module, and finally handle the wearing parts separately. Especially for precision parts such as gearboxes, the masters will use manual tools to "pick" a little bit, for fear of damaging the threads. You may not think that just this step of disassembly can help customers save 15% of the transformation cost. After all, how long the old parts can be used depends on whether there is "leniency" when disassembling.
2. Modular assembly, let efficiency and quality fly together
Disassembly is meticulous and assembly is more sophisticated. "Modular assembly" is popular in the industry now, but our factory is more thorough. For example, for the high-speed packaging line customized for food factories, we will divide the film supply mechanism, sealing and cutting module, and conveyor belt into three independent units for installation. Each unit is first debugged to the best state at its own workstation, and then assembled like Lego.
There are two advantages to doing this: first, the problem can be quickly located without dismantling the whole machine; second, it is worry-free for later maintenance. Last year, a customer reported that the sealing temperature was unstable. We directly remotely guided them to replace the heating module in less than two hours, without stopping the machine for major repairs.
3. The "three-hands-on" principle before final assembly
When it comes to the final assembly stage, our quality inspectors are busier than the production line. In the first round, check the clearance of the parts, measure the bearing seat with a feeler gauge, and measure the parallelism of the guide rail with a micrometer; the second round of power-on test run, focus on listening to abnormal sounds and feeling vibrations; the last round simulates customer working conditions and runs continuously without load for 8 hours. Last month, a machine was re-adjusted for an entire afternoon because the conveyor belt was found to be 0.5 mm off during final assembly. A colleague murmured: "The customer won't be able to find this error, right?" But our technical director made sense: "If you let it go by 0.5 mm today, you may lose an old customer tomorrow."
Fourth, "plant" maintenance skills into the equipment in advance
After working for so many years, I have realized a truth: good equipment should not only be fresh when it leaves the factory, but also be able to withstand the test of time. So we will "bury Easter eggs" during assembly - for example, post a QR code in the circuit box, and you can see the disassembly tutorial of the corresponding module by scanning the code; or engrave the maintenance cycle scale on the bearing seat. Recently, we have added quick-release buckles to the chain of the production line we made for a daily chemical company, so that customers can save half the time by replacing accessories themselves.
I remember that when I visited last year, a customer in Shandong patted the equipment and said: "Your machine is so easy to disassemble and assemble! Even the new technicians can repair it after reading the tutorial twice." This sounds more comfortable than getting a bonus.
Conclusion
From the strength of removing a screw to the "devil test" before the whole machine leaves the factory, our factory recognizes one principle: doing simple things to the extreme is competitiveness. Now every time I see the packaging machines being disassembled and assembled in the workshop, I feel that they are like our own children - which screw has been tightened for a few turns, which gear has been replaced with new teeth, we know it in our hearts. Why do we dare to promise a two-year warranty? The confidence is accumulated in this standardized process day after day!
