Why Is It Imperative To Automate Hardware Processing? Labor Shortage Is Forcing Rigid Demand

Why is it imperative to automate hardware processing? Labor shortage is forcing rigid demand

In the past ten years, the hardware processing industry has been hit hard by both labor shortages and customer demands. However, the scrap rate has always remained high, which has resulted in the factory's profits becoming increasingly slim. It's not that there is a question of whether to automate or not, but that if you don't automate, there is no way to survive.

Labor shortage makes scrap rate out of control

Young people are reluctant to enter workshops. The average age of polishers and machine tuners is over 45 years old. In 2016, there was a hardware factory in Taizhou, Zhejiang. However, because the old master resigned, the scrap rate soared from 3% to 12% for three consecutive months. Manual operation is all based on feel. Novices will inevitably encounter burrs and missed throws when they first start operating, and the rework costs will directly eat up profits.

The equipment will not cause errors due to fatigue. There is a CNC abrasive belt deburring machine. When the relevant parameters are set, it can run continuously for up to 12 hours, and the surface treatment of each product is very similar and without any difference. After the machine replaces manual operation, the proportion of scraps can be controlled within 0.5%.

Labor costs are high but scrap costs are even higher

There is a skilled polisher whose monthly salary is 7,000 yuan. The annual salary and social security add up to more than 120,000 yuan. How to reduce the scrap rate of hardware parts processing ? However, what is even more terrible is that he makes 5,000 pieces of goods every month, 200 of which may be returned due to surface defects. For each piece returned, the total cost of materials, logistics fees and customer fines are at least 50 yuan, which means that a monthly loss of 10,000 yuan will be made out of thin air.

An automated deburring equipment with an investment of more than RMB 100,000 can be used for ten years. It will neither get upset nor miss throws. After the processing parameters are locked, the daily output is stable. After calculation, the daily cost of the equipment is less than 50 yuan, and it can also avoid the loss of returns due to scrap products.

Customer review forces scrap rate to meet standard

Auto parts manufacturing plants and hydraulic system manufacturers have long regarded scrap rate as a key indicator for supplier assessment. In 2020, a hardware factory in Jiangsu received the following notice from a major customer: If the scrap rate is higher than 2%, the cooperation qualification will be directly cancelled. So they installed two roller brush deburring machines overnight, and finally reduced the scrap rate from 4% to 0.3%, thus keeping the order.

Small batch custom orders are becoming more and more common. In the past, the quantity was 10,000 pieces, but now it may be 1,000 pieces, and delivery must be completed within three days. Model changeover on a manual production line depends on the specific emotional state of the master. Model changeover on automated equipment only takes five minutes. Flexible production can directly reduce the risk of scraps during the model changeover.

Automation is not a topic for people to choose. How to reduce the scrap rate of hardware parts processing . It is a key issue related to survival. At what level is the scrap rate of your factory controlled? Tell us about the most difficult problems you have encountered in the comment area. Those who like and bookmark this article will see their orders increase exponentially this year.