Human resource allocation for PVC automatic sealing machine maintenance
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The packaging section of the factory is equipped with 3 fully automatic large-packaging machines (1.2 T/bag) + 3 fully automatic 25 KG small-packaging sealing systems (automated bag insertion, no manual bag wrapping; designed capacity of 800 packs/hour, actual capacity of 700 packs/hour)； Automatic bag suction, automatic opening of bag openings, automatic material feeding and weighing, automatic sealing and pushing of bags, transportation, re-checking and weighing, metal detection, automatic robotic stacking, etc.). Among these, the DS-7A sewing machine has a high failure rate; it needs to be repaired almost every shift. The main problems are broken wires and loose connections, and the situation has improved slightly after gaining more experience in repairs (Equipment source: Packaging components from well-known domestic brands; measuring components imported from Taiwan). I would like to ask everyone here: 1. Does anyone use a fully automatic packaging system? Is the maintenance done in-house for the machinery and electrical equipment, or through external services? How is it working? 2. How many fully automatic sewing machine packaging lines are there? Is it the third shift doing the maintenance? Should a fault still trigger maintenance (with staff on standby)? Currently, only day shift maintenance is provided (8:00–17:00), but since the packaging systems operate 24/7, faults often occur even after the night shift staff leave, requiring them to return home to fix the issues, which is very troublesome. I would like to ask whether your factory employs three shift systems for maintenance
The instruments in Taiwan are not considered imported. Thoroughly resolve connection loss and skipping issues. Mechanical and electrical instrumentation services available on demand. The operator acts according to production requirements. The repeated occurrence of problems indicates that they are not thorough in handling them.
The problem with broken or loose threads isn’t necessarily related to the sewing machine; it could also be an issue with the thread itself, such as insufficient strength, or there might be problems with the sewing machine’s settings that cause frequent thread breaks. These days, minor problems are usually repaired by the packaging operators themselves. Sometimes they feel that the packaging machines are difficult to maintain, and the company cannot obtain the necessary parts; they also don’t have lathes to fabricate parts such as cutting tools, and there are no tools available to sharpen dull blades. There are also the problems with Yidian; most of the maintenance workers for packaging machines really don’t understand how to do their job. Each factory has its own management system. In the current environment characterized by efforts to reduce staff while increasing efficiency, it’s possible to save as much as possible, but certain elements are still essential. After all, it’s better to have professionals on hand – people who aren’t just ordinary mechanics who spend hours trying to figure out the problem, which affects the production volume. There are accessories available, and it’s necessary to buy high-quality ones; delaying production is not acceptable. Personal opinion
Poster, could you share the operating procedures and flowchart for the ton bag machine? For the equipment used by that company, how many people are currently operating one ton-bagging machine?
It’s definitely better to handle mechanical and electrical maintenance by oneself; it’s also easier for training people. Find the root cause and address it (if things keep breaking every day, the root cause hasn’t been identified). It’s good to be available on call; no factory has dedicated shift workers for such faults. Training can be provided to the operators themselves, allowing them to handle some minor faults on their own. Strengthen regular maintenance to reduce the failure rate.
A tonnage packaging line is usually operated by one person; an additional forklift driver is needed to lift the packaged tons of material to the designated location. If you need to view videos of the users on site, please contact me: QQ: 42451141, Mobile: 18921271037, Wu
After the full-automatic line is actually put into use, the number of personnel required is not less than that of a semi-automatic line, and it also demands higher qualifications from maintenance staff. High failure rates are a common phenomenon nowadays; the longer it is used, the more workers will find it inconvenient to use, until they eventually refuse to use it.
It’s a shame that videos can’t be uploaded, right? It can be uploaded earlier
The video can be compressed and the compressed file uploaded
I also faced the same problems as the original poster here: inadequate skill in handling tasks, unprofessional maintenance work, mutual shirking of responsibilities among mechanical, electrical, and instrumentation teams, and slow responses. The current solution is the integration of mechanical, electrical, and instrumentation for maintenance. A 24-hour duty system is in place, with availability on call at any time. The effect is good.
Can it be packed in ton bags by one person? How is it achieved? Is it possible to do this task by oneself with a hanging bag? I’d like to discuss it.