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Company Background: A Sri Lankan manufacturer seeking to establish a high-volume mattress production facility with a target output of 200 mattresses per day.
Challenge:
- Achieve daily production target of 200 mattresses
- Ensure consistent foam quality across high volume production
- Maintain efficient cutting and finishing processes
- Balance automation with flexibility for custom sizes
- Optimize production workflow for maximum efficiency
Comprehensive Solution for High-Volume Production: We implemented a comprehensive foam production line consisting of three key components:
- SR-SAF01 Box Foaming Machine
- Equipped with dual foaming molds
- Daily production capacity of 60 foam blocks
- Consistent foam quality control
- Efficient molding process
- Meets base material requirements for daily target
- SR-HC03 Circular Disc Horizontal Cutting Machine
- Massive 10.5-meter diameter working platform
- Simultaneous cutting capability for 10 foam blocks
- Accommodates foam dimensions of L2000 x W1500mm
- Automated cutting system for high efficiency
- Significantly reduces processing time
- Maintains precise cutting accuracy at high volumes
- SR-V03 Vertical Foam Cutting Machine
- Precision edge trimming capabilities
- Flexible manual operation for special size requirements
- Custom size adjustment functionality
- Quality finishing for mattress components
- Versatile processing options for varied product specifications
Results Achieved: The implemented solution delivered significant operational benefits:
- Achieved daily production target of 200 mattresses
- Optimized production workflow through efficient equipment placement
- Reduced processing time with multi-block cutting capability
- Maintained product quality across high-volume production
- Provided flexibility for custom size requirements
- Enhanced overall production efficiency
Our Key Performance Metrics Cover
- Daily foam block production: 60 units
- Simultaneous cutting capacity: 10 blocks
- Processing dimensions: L2000 x W1500mm
- Production target achievement: 100%
This case study demonstrates our ability to design and implement complete production solutions that balance high-volume automation with the flexibility needed for custom manufacturing. The combination of efficient foaming, mass cutting capability, and precise finishing operations creates an optimal production environment for large-scale mattress manufacturing.
Enhancing Efficiency in Mattress Manufacturing
The success of this project highlights our expertise in scaling foam production while maintaining product quality and manufacturing flexibility. The solution provides our client with the capacity to meet their ambitious production targets while ensuring consistent quality across their product line.
