Turnkey - Plant Automation
In the era of network, the old saying "time is money" is undoubtedly true. Customer orders that are delayed result in business losses and a ruined reputation. You'd want your company to flourish with an excellent working environment. So, how will you achieve it? Here's when adapting turnkey automation may prove to be beneficial. Read on to find out why your company must look to adapt a turnkey automation method for a whole plant automation production line.
What is Turnkey Automation?
A turnkey automation system, when implemented correctly, may assist in coping with shortage of workers, high wage inflation and operational efficiency. With this service you can drive lean practices and simplify production processes while also ensuring compliance requirements. G-way Company offers a wide range of customized automation solutions for fully automated systems, all over the world. It is difficult to run a production line programme smoothly, which is why we offer specialized services as per your requirements. When compared to a traditional technique, this consultant-led production line procedure can be finished in less time.
How does the process work?
Even though this approach is consultant-driven, it follows many of the same phases as the conventional method. Customers can get a whole plant automation machinery for their specific needs.
Planning, discovery/setup/configuration, model review and training, meeting room trial, switchover, and go-live support are the six essential phases in the whole plant Turnkey approach.
Why is it beneficial to adapt?
Whole plant Turnkey projects are a method to profit handsomely from the expertise needed to construct and operate a technologically sophisticated operation. You can get various services like automatic edge selection, feeding of rubber and iron shells, automatic assembling, measuring and unloading. And all of this is only a small part of the services offered!
How can industries automate production processes?
While many businesses want to automate to boost productiveness, building machines to accomplish these goals is not always straightforward. It's quite likely that it would have happened if all procedures were simple to automate. Businesses must also determine if investing in automation will provide a profit rather than simply wind up in pricey junk.
The automation plan is frequently driven by the entire project's demands as well as market uncertainties.
Every project is unique, but you can generally approach it in one of two ways:

  • A method that allows you to gain a comprehensive knowledge of a specific automation problem.
  • A higher-level strategy that permits a larger problem to be solved or more inventive leaps to be taken. It may entail various production methods.
What stability does the Turnkey model offer?
In global business, Turnkey contracts or activities are prevalent in the supply, construction, and activation of factories. Turn-key operations are a form of a joint venture in which one firm engages with another to construct fully functional, ready-to-use facilities.
In addition to removing much of the danger, choosing a turnkey model rather than a consigned method can save a firm like the one described above more than $107,000 per year.
Complete automation can increase total throughput by 33 percent or more while decreasing individual unit costs. Turnkey automation has the advantage of providing rewards not just to you, but also to your supplier and consumer.

Turnkey Project Case Study

The latest auto loading and unloading production line for oil seal vulcanization:
  1. The metal case and rubber are automatically fed into the loading jig.
  2. The transportation system transports the fixture to the compression molding machine.
  3. The loading mechanism will push the loading fixture into the mold.
  4. The oil seal is pushed into the compression molding machine and vulcanizing it.
  5. The unloading mechanism out-feed the finished product from the molding press and cools it.
Oil seal trimming and defect inspection system:
  1. The vulcanized oil seal is directly fed into the cassette stack.
  2. Auto in-feed system will take out the oil seal one by one and put it into the trimming machine.
  3. Auto trimming machine trims the main lip of the oil seal and removes the flash.
  4. The machine checks 5 points of the dimension and defect of the seal.
  5. Sorting the OK/NG products and stacking in cassette of finished products.
Combined oil seal injection molding and trimming machine in the production line.
  1. Rubber raw material is transported through a pipeline from the rubber barrel to the injection molding machine.
  2. After molding, the oil seal enters the conveyor and is fed into the feeding system for trimming.
  3. The co-robot checks whether the oil seal is front or back side, flips the seal, and puts the seals onto the trimming jig.
  4. Auto trimming machine trims the main lip of the oil seal and removes the flash.