Hardware factory profits wiped out?

1. Counting errors occur frequently and after-sales deductions are difficult to guard against.

Small hardware parts are small in size and large in batches. Traditional production relies entirely on manual counting and manual packaging. After repeated boring work for a long time, it is normal for workers to suffer visual fatigue and neglect to omit numbers. Problems of installing less, more, or mixed screws of different specifications frequently occur. At present, core customers such as home appliances, furniture, and auto parts have extremely strict requirements on the accuracy of accessories packaging. Even if there is only one screw missing in a single package, the entire batch may be returned, deducted, and cooperation canceled, which will invisibly cause huge rework costs and customer loss.

2. Labor costs remain high, and recruitment and retention are in an endless cycle.

The screw packaging position is mechanically boring, repetitive, and work-intensive. It is the position that young people are least willing to do. Hardware factories have been facing the dilemma of recruiting workers and being unable to retain new workers all year round. In order to ensure the normal delivery of orders, companies can only hire packaging workers at high salaries for a long time, adding wages, board and lodging, management, overtime subsidies and other expenses, and labor costs are rising year by year. At the same time, high personnel mobility and unskilled operation by newbies directly lead to unstable production capacity, backlog of orders in peak seasons, delayed shipments, and missed a large number of cooperation opportunities.

3. The packaging is rough and easy to be damaged, and the product is rusty and has a high return rate.

Screws have sharp edges and high metal hardness. There is no uniform standard for manual bagging and sealing. The edges are loose, skewed, and have varying degrees of tightness. In the process of long-distance logistics transportation, handling and stacking, problems such as bag breakage, material leakage, and bag explosion are very easy to occur. More importantly, manual packaging has poor sealing performance and cannot effectively isolate air, dust, and water vapor. Hardware accessories are easily susceptible to moisture, oxidation, dust accumulation, and rust. Not only did the defective rate of products increase significantly, but the packaging quality was uneven, and it completely failed to meet the shipping standards of mid-to-high-end customers and foreign trade orders, directly limiting the order level of the factory.

4. Changing models of multiple specifications is cumbersome and seriously affects production efficiency.

Typical characteristics of the hardware industry: many specifications, miscellaneous categories, many small orders, and frequent order changes. One screw has one size, and the matching nuts and washers have different specifications. The debugging of traditional old packaging equipment is complicated and the operation is cumbersome. Every time the product specifications are changed, it requires a long time to shut down the machine, change the film, and calibrate parameters. It is also prone to malfunctions such as material jamming, film running, and packaging deviation. Frequent shutdowns and debugging lead to production interruptions and waste of production capacity, which are completely unable to adapt to the current flexible and multi-batch market production needs.

5. There is no data traceability in production, making it difficult to manage the factory in a refined manner.

In purely manual packaging mode, there is no accurate output statistics, batch records, and loss data. Packaging errors, material losses, and production capacity gaps cannot all be traced back to their source, and the factory can only manage them extensively. Not only is this model unable to accurately calculate production costs and optimize production processes, it is also unable to meet the quality traceability audit requirements of major customers and foreign trade companies, directly blocking the path to high-end and large-scale development of the factory.

1. Intelligent and accurate counting, zero error to eliminate customer complaint deductions

The equipment is equipped with a professional photoelectric counting + vibration blanking dual system, which provides intelligent and precise quantification. The counting accuracy far exceeds that of manual work, eliminating the root causes of problems such as under-loading, over-loading, and mixed loading. It not only supports quantitative and independent packaging of a single type of screws, but also enables mixed and matching packaging of screws, washers, and nuts. It perfectly meets the packaging needs of complete sets of furniture, electrical appliances, and auto parts. It completely solves the problems of after-sales returns and customer deductions, and solidifies the reputation of cooperation.

2. Unmanned and fully automatic operation, significantly reducing labor costs

The whole machine realizes automatic feeding, quantification, bag making, sealing, film cutting, coding and discharging, all in one fully automatic operation, without manual intervention in the whole process. A single piece of equipment can replace 3-5 workers and support 24-hour uninterrupted stable production. The production capacity is more than three times that of manual operation. Completely get rid of the difficulties of recruiting and retaining workers, and unstable labor production capacity, significantly reduce labor expenses, and improve overall production efficiency.

3. Constant temperature and precise sealing, neat packaging, anti-breakage and anti-rust

It adopts an independent zoned constant temperature temperature control system, which can accurately adjust the temperature according to the characteristics of the hardware materials. The sealing is smooth, tight, uniform and firm, without wrinkles and air leakage. The packaging film fits tightly, effectively resisting the sharp corners of the screws from puncturing the bag body, and eliminating the problems of material leakage and bag breakage during logistics transportation. The sealed packaging structure can effectively isolate dust and water vapor and prevent hardware accessories from oxidation and rust. The unified and regular bag shape comprehensively improves product appearance and shipping quality, and easily meets the acceptance standards of high-end customers.

4. One-click quick change, suitable for flexible production of multiple specifications

Equipped with a high-end three-servo intelligent control system, touch screen visual operation, one-click storage and one-click switching of parameters. Long and short screws and various small hardware parts can be quickly changed and film replaced without complicated debugging. It greatly shortens downtime and debugging time, adapts to the multi-category, small batch, and high-frequency order change production model of hardware factories, fully maximizes flexible production capacity, and effectively improves production capacity utilization.

5. Data visualization traceability helps refine factory management

The equipment comes with an intelligent data statistics system that automatically records core data such as daily output, production batches, material loss, and operating hours. The production process is transparent and traceable. It supports the optional online coding function, which can print production date, batch number, and specification parameters. It is perfectly adapted to the quality inspection and foreign trade order compliance requirements of major customers, helping factories to accept high-end orders and achieve refined and standardized management upgrades.

Free sample trial packages are sent, and exclusive packaging solutions are customized according to the materials.

Equipment can be customized on demand to adapt to different specifications and production capacity needs.

On-site installation and commissioning + technical training + lifelong after-sales service, worry-free production