SHINVA Medical Cuts AS/RS Assembly Cycle by Half

Driven by surging market demand for intelligent infection-control warehousing equipment in the first half of the year, SHINVA faced mounting pressure for order fulfillment. Targeting major pain points of the washing-rack automated storage and retrieval system (AS/RS) — numerous components, complex structures, difficult assembly and long production lead time — SHINVA Medical adopted a problem-oriented approach. Guided by DFMA (Design for Manufacture and Assembly) principles, it carried out multi-dimensional improvements covering structural streamlining, process innovation and production-mode optimization. Dual progress in assembly efficiency and product quality has been achieved, delivering tangible results for quality and efficiency enhancement.

Previously, this AS/RS involved cumbersome assembly procedures requiring three operators working collaboratively, with a full-machine assembly cycle as long as eight days. Capacity bottlenecks severely restricted order delivery performance. To eliminate production obstacles, SHINVA prioritized design-source improvements for full product-structure optimization. Redundant base holes and unused parts were removed; the split-type top cover was upgraded into an integrated monolithic structure. Traditional complex connections with inserting strips and multiple bolts were replaced by precise single-bolt fastening. High-precision square-tube profiles were adopted to substitute bent sheet-metal parts. These measures greatly cut down component counts, simplified assembly steps and reduced manual assembly errors.

On the production side, SHINVA innovatively rolled out a modular outsourced integration model. Core assemblies such as rollers, protective covers and frames are packaged as standardized integrated units for one-stop processing and assembly by suppliers. An innovative plug-in spot-welding process, inspired by mortise-and-tenon joints, enables precise alignment and one-shot spot welding of square tubes without additional reinforcing ribs. It effectively mitigates welding deformation and improves equipment rigidity, saving one full day of assembly time with this single improvement.

Thanks to these series of optimizations, remarkable quality-and-efficiency gains have been realized. Currently, the full-machine assembly cycle of the intelligent AS/RS has been halved from eight days to four days. BOM item quantity has dropped by over 80 %, and material part types have been reduced by more than 45 %. Besides lighter-weight and higher-efficiency assembly, structural stability and overall product quality have been comprehensively improved.

Going forward, SHINVA will further advance the DFMA optimization system. Technical innovation will empower higher product quality and lower manufacturing costs while unlocking greater production capacity. With faster order delivery and superior intelligent infection-control solutions, the division will consolidate its core market competitiveness.