BIUCO is deploying a smart high-end production line

The Old Story

It is always a dream of BIUCO to build a smart factory with automatic production. In 2015, the beginning year of BIUCO, we tried to build one such production line and finally changed. We’d learned a lot of things during this trial, some are useful experiences (automatic injection molded part production, packing automation) and some are precious lessons (). The practice of smart factories may change over time, but the sparkle of exploration is never extinct.

The New Background

From 2017 to 2021, BIUCO had enjoyed rapid growth. Its yearly revenue had increased drastically from less than 5 million RMB to over 125 million. During this period of time, we also gain knowledge of baby product production, and acquired lots of production certificates including ISO9001, TS16949, SEDEX, and so on. Therefore, we believed it was time for us to plan and deploy a new smart factory that combines baby product manufacturing together with Lean Production.

The Target

BIUCO set a 3-phase plan to establish a dark factory-like production line based on automation, informatization, and digitization.

In a real production scenario, the ultimate goal is a full smart PO fulfillment chain. The client can put POs through APP on a personal device, and then the PO will be automatically arranged by the planning system, produced by the semi-automatic lines with live streaming shown key production stations and data, visible boards. The order status is real-time updated, and all orders and key materials are traceable in every stage in the system.

The Phases

To achieve the goal above, BIUCO divided the whole process into 3 phases:

Phase 1: Lean Production (March 2022 – May 2022 ). Through a new assembling line layout planning, SPS (Set Pallet System) distribution, new fixture jigs, and live streaming cameras will be applied in the line.

Phase 2: Informatization & Automation (May 2022 – May 2023). Deploy Manufacturing Execution System (MES, including AGV, handheld terminals, digital Kanban) and automatic machines.

Phase 3: Smart Factory (March 2023-December 2023) . A Smartphone application is developed for client & factory usage. The whole manufacturing process will be guided by the smart system.

The Layout

Since BIUCO had automatized its plastic part production, the main task is to reconsider the layout of assembling line.