Shingi Electronics is affiliated to SHIN TECH LIMITED which was registered in Hong Kong in 1993. Establishing subsidiaries in Dongguan, Japan and Vietnam, SHIN TECH LIMITED is mainly engaged in electronic products, automotive electronics, plastic injection molding. NEOTEC has grown from a factory building with more than 300 employees into a collectivized company with more than 10,000 employees and an annual output value of more than HKD 20 billion. Since 2014, it has become one of the top ten export enterprises in Dongguan and has won many awards from national, provincial and municipal governments.

As a typical OEM factory, NEOTEC mainly gains profits from OEM business. The original manual analysis and production scheduling, manual checking of materials, and whole work order based preparation material lead to low efficiency and great quality risks, which greatly affects the delivery of products to the customers. Its order structure mainly shows the following characteristics:

1. The high mix low volume production mode reveals that about 100 customers are actually served every year, but more than 10,000 product types are produced. The whole work order based material preparation mode leads to extensive cutting and material loss.

2. More than 300 work orders are produced at the same time every day, and each line has 8~10 changeovers per day on average. All materials are fed during each changeover, resulting in a long changeover time, with an average of more than 30 minutes.

1. The JIT mode is introduced to solve the problem of extensive cutting and material loss:

   break away from the traditional mode of the whole work order based material cutting and preparation, and adopt the first set + JIT mode with minimum packaging preparation. After the first set of materials is prepared, the system conducts real-time monitoring of production progress and material usage based on equipment networking, and promptly notifies the warehouse personnel of production line low material warning information through the mobile terminals and all kinds of kanban. The warehouse personnel then prepares the materials according to the warning information, and deliver the materials to the production line through AGV or material vehicles, forming the JIT mode.

   
   

2. The intelligent production switchover solution is introduced to optimize the changeover process and solve the problem of long changeover time:

   break away from the traditional mode of feeding all materials during changeover. The system conducts an intelligent analysis on the material sharing of previous and next work orders, and recommends an intelligent production switchover solution. The shared materials will be automatically transferred to the next work order, and the system will give reminders of material differences to reduce repeated material preparation, return and feeding of extensive shared materials.

1. Through the application of JIT pull feeding and intelligent production switchover, the line changeover time is reduced from 30 minutes to 10 minutes, and the comprehensive production efficiency improved by 13%, generating an annual new output value of nearly RB 100 million.

2. In the first phase, 80 employees are reduced in the warehouse and production lines, marking a direct employee reduction of 28%, saving RMB 6.4 million/year of labor costs.

3. The inventory of self-purchased materials is reduced by 30%, WIP reduced by nearly 60 million, and all kinds of paper production statements reduced from 1140 copies to 0 copy.