At five o'clock in the morning, the puffed food workshop was filled with the aroma of corn, but Zhang Wei, the production supervisor, had no time to enjoy it. He stared at the old packaging line in front of him with a frown - this equipment that had been in service for ten years had just experienced the 23rd jamming failure, and there were only 72 hours left before the delivery of the Mid-Autumn Festival gift box order. The turning point came in an emergency meeting with the ply-pack technical team: "We can make this intelligent packaging production line transform while producing, just like changing the engine of an airplane in flight."
The company's original packaging production line was composed of 6 independent devices in series, and each time the product specifications were switched, it took 8 hours to adjust the parameters. "It's like using an abacus to process big data." The equipment section chief laughed at himself at the project launch meeting. What's more difficult is that the rigid structure of the old machinery is not compatible with the newly developed mini packaging specifications, causing the company to miss the order bonus of the young consumer market.
The "live surgery" solution proposed by ply-pack includes three major innovations:
.Intelligent packaging production line nerve center: implant a dynamic sorting system to scan product specifications in real time through millimeter wave radar;
.Magnetic modular upgrade: replace the traditional fixed sealing unit with a slidable intelligent module to support fast switching of 5 processes such as heat sealing and ultrasonic waves;
.Energy efficiency optimization dark channel: deploy an energy recovery device in the equipment interlayer to convert the heat energy generated by mechanical braking into driving power.
The technological breakthroughs during the transformation are amazing. Engineers use the 2-hour cleaning and disinfection window of the puffing workshop every day to gradually replace the production line components like assembling Lego. When the third module was online, the operating robot arm suddenly adjusted the grasping trajectory autonomously-the built-in AI vision system recognized the reflective material of the new packaging bag and instantly reduced the grasping pressure from 12N to 8N to avoid the breakage of crispy chips.
The upgraded smart packaging production line shows amazing flexibility:
·Product changeover time is shortened from 8 hours to 23 minutes
·Compatible specifications are expanded from 3 to 28
·Energy consumption peak is reduced by 37%
What surprised the purchasing director the most was that the daily production capacity increased instead of decreased during the transformation: "Those buffer modules that can 'breathe' have increased the effective operation rate of the equipment by 15 percentage points."
At the completion ceremony, Zhang Wei stroked the warm equipment shell and said with emotion: "These steel giants with data blood flowing through them have retained the solidity of traditional machinery and the agility of digital life." Today, this packaging production line is spitting out the newly developed quinoa crisps at a speed of 120 bags per minute, and the energy efficiency curve jumping on the large screen in the control room is like the electrocardiogram of the company's intelligent transformation.
