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Roller Conveyor Line Upgrade: Efficiency Doubling Case in Washing Machine Factory

2026-01-16

A large-scale washing machine factory (annual capacity: 500,000 units) faced traditional production bottlenecks:

Poor line adaptability: Single conveyor line only compatible with 1-2 product models; model changeover took over 8 hours

Inefficient logistics coordination: Manual semi-finished product handling resulted in 23% daily ineffective working hours and over 30 minutes of material waiting time per unit

High quality risk: 2.5% collision rate during transportation leading to high rework costs

Gap with international standards: Disparity with automated logistics systems of global enterprises like Whirlpool

II. Three-Dimensional Solution: Intelligent Upgrade of Roller Conveyor Line

1. Core Equipment Reconstruction: Flexible Roller Line Design

Dual-row 304 stainless steel roller layout (referring to industrial design logic): Roller spacing precisely matches washing machine body curvature, improving transportation alignment by 95% and avoiding offset collisions

Rubber-coated surface: Buffer design reduces workpiece damage rate to below 0.8%

Modular quick-change interface: Pneumatic locking device enables 15-minute rapid reorganization of functional units

2. Intelligent Collaboration System: AGV + Roller Line Linkage

Deployed MiR200-class autonomous mobile robots (aligned with Whirlpool's solution): Automatically transport materials between roller lines and pre-assembly areas, with single-load capacity of 12 washing machine components and one-way 130m transportation cycle ≤4 minutes

Fleet management system: Dynamically schedules robot queues and monitors battery levels to ensure 24/7 continuous operation

UWB positioning technology: Reduces material delivery response time to 90 seconds and cuts work-in-progress inventory area by 55%

3. Process Optimization: Human-Machine Collaboration & Beat Control

Ergonomic unloading area: 460mm-wide operation channel + 300mm height adaptation reduces employee bending movements and lowers labor intensity by 40%

Speed chain beat control: Standardized 8-second/station operation eliminates process congestion, increasing line balance rate from 72% to 93%

Embedded inspection units: 21 sets of visual inspection equipment monitor transportation quality in real-time, achieving 99.92% defect recognition accuracy
IV. International Benchmarking & Industry Value
- Benchmarked against Whirlpool Poland Factory: 30% shorter transformation cycle, 40% lower investment cost, better adapted to multi-variety small-batch production
- Core advantage: Balances "flexibility + cost-effectiveness", saving RMB 6 million compared to fully imported solutions
- Replicability: Successfully applied to 3 main washing machine production lines, supporting mixed-line production of drum and top-loading models

Hydraulic Cargo Lift

Industrial Hydraulic Lift

Industrial Goods Lift

Freight Platform Lift

Mobile Dock Ramp

Hydraulic Dock Ramp

Dock Leveler

Loading Dock Leveler

Fixed Dock Leveler

Fixed Scissor Lift Platform

Hydraulic Scissor Lift Table

Mobile Scissors Lift

Reciprocating Vertical Conveyor

Roller Conveyor

Double Speed Chain Conveyor

Chain Conveyor

Palletizer Machine

Depalletizer Machine

Container Ramp

Flatbed Trailer

Hydraulic Cargo Lift

Industrial Hydraulic Lift

Industrial Goods Lift

Freight Platform Lift

Mobile Dock Ramp

Hydraulic Dock Ramp

Dock Leveler

Loading Dock Leveler

Fixed Dock Leveler

Fixed Scissor Lift Platform

Hydraulic Scissor Lift Table

Mobile Scissors Lift

Reciprocating Vertical Conveyor

Roller Conveyor

Double Speed Chain Conveyor

Chain Conveyor

Palletizer Machine

Depalletizer Machine

Container Ramp

Flatbed Trailer

Roller Conveyor Line Upgrade: Efficiency Doubling Case in Washing Machine Factory

Roller Conveyor Line Upgrade: Efficiency Doubling Case in Washing Machine Factory