In the field of global printer consumables, product quality and production efficiency are the key to a company's core competitiveness. The case shared in this issue is Tianwei Group, a well-known multinational enterprise in Hong Kong, China. Through in-depth analysis, we can understand how Lingke Ultrasonic assisted Tianwei Group in connecting the entire production line chain, achieving a breakthrough in production efficiency by 200% and a defect rate reduced to 0.5%, providing key support for seizing the domestic market.
Customer background: Tianwei Group's localization upgrade needs
Tianwei Group is a leading enterprise in general consumables for printers, with products covering high-precision consumables such as 3D printers, ink cartridges, and toner cartridges. Its Zhuhai production base urgently needs to upgrade its core component (ink cartridge/toner cartridge) production line to meet the strict quality requirements of high sealing and high precision in order to adapt to the rapidly expanding domestic market.
Core challenge: Triple dilemma of technology, efficiency, and production line
01 Technical Challenge: Tianwei Group used traditional adhesive welding methods in the past, which not only had poor sealing, but also easily contaminated the internal structure, seriously affecting the beauty and cleanliness of the products. In today's market environment where consumers have increasingly high demands for product quality, traditional craftsmanship cannot meet the requirements for sealing, precision, and appearance.
02 Efficiency pressure: Large sized ink cartridges/toner cartridges need to be welded multiple times, and the process is complex, resulting in poor quality consistency and high scrap rates. Repeated welding leads to fluctuations in yield and rising costs, making it difficult to support large-scale production and putting the enterprise at a disadvantage in market competition.
03 Production line collaboration：Multiple welding processes result in lengthy production lines, making it difficult to match the rapidly expanding demands of the domestic market. With the continuous development of the domestic market, the order volume is increasing day by day, but the existing production capacity cannot meet the market demand in a timely manner, which seriously restricts the development of enterprises.
Lingke Solution: Customized Equipment+Whole Process Optimization
01 Customized multi head high-power ultrasonic welding equipment
① For large-sized ink cartridges/toner cartridges, we have developed a multi head high-power ultrasonic welding machine to achieve efficient one-time welding and industry-leading power stability.
② The equipment supports high-precision control to ensure welding sealing and cleanliness meet the standards.
02 Whole process process optimization
① Lingke resident engineers collaborate to design welding plans, optimize assembly line layout and transportation checkpoints, and eliminate process bottlenecks.
② Combining digital upgrading to improve the efficiency of production process connection.
03 Technical Empowerment and Training
① Provide professional training for the operation team to ensure efficient operation of the equipment.
② Assist customers in solving upstream and downstream supporting problems and promote digital production upgrading.
Customer benefits: triple breakthroughs in efficiency, quality, and cost
01 Efficiency Breakthrough
The welding process time has been reduced by 67%, production efficiency has been increased by 200%, and daily production capacity has doubled.
02 Quality leap
The defect rate has decreased from an industry average of over 5% to 0.5%, and the sealing and cleanliness meet international standards.
03 Cost optimization
Reduce equipment maintenance costs by 30% and shorten production line processes by 20%, helping to quickly recoup costs.
Value point of the case: The perfect combination of technological barriers and deep cultivation of scenarios
Tianwei Group has successfully launched the first high-precision toner cartridge in the domestic market, establishing its position as a technological benchmark in the industry.
The upgrade of digital production helps enterprises quickly respond to market demand and seize market share.
Lingke Ultrasonic focuses on technology and delves into customer production scenarios, providing full cycle services from equipment customization to production line upgrades, empowering manufacturing customers to achieve triple breakthroughs in "quality efficiency cost". The case of Tianwei Group fully demonstrates the advantages of Lingke Ultrasonic in technology research and service capabilities, and also provides valuable reference experience for other manufacturing enterprises.
For more application cases of ultrasonic welding, please contact Lingke Ultrasonic!
