Nantong Coship Intelligent Manufacturing Tour

Founded in 1994, Shenzhen Tongzhou Electronics Co., Ltd. is a high-tech enterprise focusing on providing leading smart home products and services for global users. The company continues to actively expand the layout around the strategic development idea of ​​"smart continent, connect the future", continuously enhance the company's core competitiveness, and further expand multi-functional smart set-top boxes, smart routing, smart gateways, smart speakers, network broadband products, digital front-end Equipment, as well as the research and development and promotion of the new generation of DVB+IP+OTT business integration platform, to consolidate the innovation and market advantages of the business integration platform and smart home business. On this basis, the company actively deploys emerging fields and markets such as smart homes, smart communities, smart buildings, smart parks and the Internet of Things, and expands new growth space through resource integration and model innovation. Comprehensively assist operators to upgrade to "smart" and "Internet of Things", and promote the development of the global digital video and Internet of Things industries. At the same time, the company is also actively evaluating and exploring new applications of artificial intelligence, 8K , 5G and other new technologies in the video field.

With the in-depth layout of Tongzhou's global digital video end-to-end business, Nantong Tongzhou's video terminal manufacturing business has grown rapidly for three consecutive years. Up to now, the production volume has increased by nearly 50% compared with the same period last year . Factory demand for high-end equipment and skilled operators remains high. Although the current production is in full swing, there is a shortage of personnel in all positions. On the one hand, Nantong Tongzhou actively coordinates human resources, encourages employees to work harder, and encourages management cadres to go to the grassroots; on the other hand, it has also started to fundamentally solve this problem from the perspective of intelligent manufacturing. question.

At present, the manufacturing industry is facing many "survival" crises; on the one hand, the continuous rise in labor and material costs has greatly increased the production cost of the factory; on the other hand, orders are becoming more and more discrete, and the demand for personalized customization is increasing. , The factory has many innovative products that need to be produced and delivered in time, and the business model of products is changing. Facing the transformation of the new market economic environment, the production technology of the manufacturing industry has also undergone great changes. The advent of the Internet of Things technology, robotics technology, artificial intelligence technology, cloud technology, and big data has brought about the situation of the manufacturing industry. The big change, that is intelligent manufacturing! Intelligent manufacturing is born for the current predicament of the manufacturing industry! Nantong Tongzhou is a standard labor-intensive manufacturing factory as a set-top box product manufacturing factory. Therefore, Nantong Tongzhou's development and realization of intelligent manufacturing is of "epoch-making" significance, which not only lays the foundation for the company's transformation from labor-intensive manufacturing to automated intelligent manufacturing , and will also become a new benchmark in the set-top box manufacturing industry.

Since the establishment of the "Intelligent Collaborative Robot Automated Production Test Development" project team in October 2018, Nantong Tongzhou has successively carried out the selection and verification of applicable robots; in order to adapt to the operation mode of the factory's inherent belt production line, it has focused on the development and verification of intelligent robots. "Indeterminate speed" visual effective recognition system; in order to adapt to the complexity of the test interface of the set-top box and to realize the effective grasping, plugging and unplugging of the set-top box by the robot, a special robot "gripper" and special tooling fixtures are carried out. It is ahead of other supporting hardware design solutions in the collaborative robot industry, and has created two compatible intelligent robot operating hardware platforms, "tiling method" and "stacking method", to effectively improve operation efficiency and stability; In order to realize the transformation of the set-top box test from the artificial sensory and visual judgment test method to the intelligent automatic test method, the project team completed the development and verification and realized the interaction between the intelligent robot software system and the set-top box test software system; in order to effectively realize the intelligent test of the intelligent collaborative robot Operation, the project team develops and implements a user interface operating system based on android pad for robot management and configuration to meet the needs of intelligent and simple operation and diversified product testing. To sum up, under the circumstance of effectively completing the software and hardware development of the four aspects of automated test production of intelligent collaborative robots, Nantong Tongzhou will introduce intelligent robot production operations according to the plan to enhance market competitiveness and achieve sustainable development of Tongzhou Electronics. work towards strategic goals.

Nantong Tongzhou factory currently has nine SMT production lines, three DIP production lines, two OEM production lines, and five production lines for complete set-top box products, testing and packaging. The "software/hardware" supporting production facilities are complete, and the monthly production capacity of set-top box products can meet 500,000 delivery of the table. At present, the set-top box business mainly includes S4110 series, S4100 series, S4020 series, N9300 series, etc. of domestic customers in Jiangsu, Zhejiang, Guangxi, Guangdong, Guizhou and other regions; the international set-top box business mainly includes Sri Lanka, Colombia, the United States, India, Russia, Brazil, N8784B, N8783C, N8786C, CCM8200, N8774U, N8784H, etc. from customers in Malaysia, Nepal and other countries; OEM production capacity is about 200,000 units per month; the production line is busy, and employees work overtime to complete production Task. In the future, after the full introduction of intelligent collaborative robots in Nantong Tongzhou factory to realize intelligent manufacturing and production operations, the monthly production capacity of set-top boxes will exceed 600,000 units, while the monthly production capacity of OEM products will exceed 300,000 units. 600 people are reduced to 150 people, which will greatly improve production efficiency and reduce labor costs.

Nantong Tongzhou Electronics plans to introduce intelligent collaborative robots for production operations as follows:

n   "Phase I" will introduce "complete machine testing robots" for three production lines, reduce the 48 test manpower produced by the original manual operation to 12 , and directly replace 36 test manpower with intelligent collaborative robots, and the annual labor cost will be saved by about 2 million; the efficiency of production testing will be increased to 120%, and the leakage rate of manual testing can be effectively avoided in terms of test quality, which can effectively strengthen the reliability of testing. Improve shipment quality and enhance customer satisfaction.

n  "Phase II" will develop and introduce intelligent collaborative robots to automate production operations in the assembly and packaging of set-top boxes, reducing the 87 groups and manpower produced by original manual operations to 27 groups and manpower, and directly using intelligent collaborative robots instead With 60 teams and manpower, the annual labor cost will be saved by about 3.3 million. By integrating the whole machine testing manpower replaced by intelligent robots, the three lines of the set-top box machine production workshop will save about 5.3 million labor costs per year. It is expected to save 30 million labor costs for the company in the next five years.

n  "Phase III" will develop and introduce alternative production operations of intelligent robots for the whole process.

At the same time, in order to improve OEM customer satisfaction, improve on-site 7S management and quality management capabilities, and combine the production capacity of the fourth quarter, the SMT workshop line body is specially re-arranged and reconfigured to meet the needs of OEM and set-top box business. Reconfigured and expanded to 8 lines, the production capacity has been increased from the previous 15,000 units/day to 25,000 units/day, the equipment capacity has increased by 66.7%, and the SMT product delivery time has been shortened from the previous 4 days to 3 days. A substantial increase.

Under the general trend of "life and death transformation" in the manufacturing industry, Nantong Tongzhou will not forget its original intention, forge ahead, and strive to embark on the road of intelligent manufacturing!