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Case Study: Line Upgrade Success Story – Doubling Output for Labor Protection Face Vent Valves

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Case Study: Line Upgrade Success Story – Doubling Output for Labor Protection Face Vent Valves

04/02/2026

Increasing production capacity is a common goal, but doing so efficiently and sustainably is the true measure of a successful upgrade. This case study showcases how a comprehensive line modernization project doubled output for labor protection face vent valves while improving overall equipment effectiveness.

A manufacturer of essential labor protection face vent valves faced a significant challenge: meeting a sudden surge in demand while operating at maximum capacity on aging equipment. Simply adding a second shift was not enough; a fundamental line upgrade was required to double output without compromising quality or worker safety. TYM partnered with the client to engineer a transformative solution.

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The upgrade began with replacing the old hydraulic LSR machine with a new, high-speed, all-electric model. This alone reduced cycle time by 20%. A new multi-cavity hot-runner mold was installed, increasing cavitation from 1-up to 4-up. Most importantly, a fully automated downstream cell was integrated, featuring a 6-axis robot for part removal, a dedicated cooling conveyor, and an automatic vision inspection station.

The results were remarkable. Not only did the line achieve its goal of doubling output, but Overall Equipment Effectiveness (OEE) increased from 65% to 88%. Downtime due to quality issues plummeted as the automated inspection caught defects immediately. Labor costs per unit decreased significantly as manual handling was eliminated. This project demonstrated that strategic investment in integrated, automated solutions is the most effective path to sustainable capacity expansion.