In the field of electric kettle heating plate manufacturing, high defect rates are an "invisible killer" that erodes company profits. Recently, one of our Bangladeshi customers encountered challenges while operating a 6-station heating plate brazing machine for kettles, resulting in a brazing defect rate as high as 10%. This not only caused material waste but also severely hampered overall production efficiency.
Upon receiving feedback, our engineering team didn't just provide online guidance; they arrived at the customer's factory in Bangladesh within 48 hours to conduct on-site diagnostics. The problem was quickly identified – it wasn't an equipment issue, but a systemic challenge involving process parameters such as material composition, heating plates, heating tubes, and stainless steel base plates.
Leveraging our dual identity as both an "electric kettle manufacturer" and a "specialized kitchenware making machine manufacturer," our engineering team quickly developed a comprehensive solution:
|
Parts |
CUSTOMER PROBLEM |
PICTURE |
SOLUTION |
REMARK |
|
Aluminum disc |
1. The brazing liquid coating on the aluminum disc is too thick and uneven, 2. The brazing liquid is too thick |
|
1. The ratio of brazing liquid should be 1:1:7 (brazing powder: agent: water) 2. Replace with a 2-inch brush, increase the brushing area, and reduce the brushing times |
Excessive coating of the aluminum disc brazing powder will definitely cause deformation of the heating plate after brazing |
|
SS. plate
|
1. Too many oil stains on the surface 2. There is a problem with the punching mold, resulting in uneven surfaces
|
|
1. The ratio of the cleaning tank should be 1:3:400 litres (acidic cleaning liquid: agent: water), soaked at 70 degrees for 5-10 minutes 2. Improve the punching mold.
|
1. The cleaning and soaking time of SS discs should not be too long, otherwise it will cause the surface oxide layer to be damaged and the surface to turn black, 2. SS disc cleaning standard: After cleaning, no water droplets should hang, and surface water stains should naturally flow down 3. There is no problem with the cleaning process of Al discs 4. We suggest soaking the SS. plate for 5-10 minutes in a chemical liquid pool. And wash away the oil floating on the water surface with the water flow in a normal water pool
|
While outlining the problems and solutions, our engineers provided on-site training to the customer's team, teaching them standardized operation and daily maintenance procedures. Within a week, the brazing defect rate on the production line dropped steadily from 10% to below 1%. This meant the customer directly benefited from:
1. Significant cost reduction: Material waste was reduced by over 90%, and rework costs were virtually eliminated.
2. Significant capacity increase: The production process became smoother, effectively increasing daily output.
3. A leap in quality and reputation: Product consistency was significantly improved.
Why can Davinci Machine solve the customer's problem?
Because for Davinci, we deliver more than just a machine. Our core advantage stems from our unique "manufacturer + equipment maker":
1. Professional depth rooted in manufacturing: We ourselves are professional manufacturers of kettle heating plates and full kettle production. We understand every pain point in production – which solder has the best fluidity, which temperature curve balances strength and appearance, and what kind of fixture design can prevent cold soldering. This "process knowledge base," accumulated from millions of products, is directly encoded into our equipment design and debugging standards.
Service speed rooted in equipment expertise: We understand the cost of production line downtime. Therefore, our service commitment is "rapid response, problem eradication." We don't just send equipment repair technicians; we also send process engineers who understand production, ensuring that the solution is systemic and long-lasting.
3. A Customer-Centric Cost Perspective: We always consider problems from the perspective of our customers' overall production costs. The value of excellent equipment lies not in its low price, but in its ability to minimize waste, improve yield, and stabilize output. Our goal is to minimize our customers' unit production costs through a comprehensive solution encompassing "equipment + process + training."
If you are looking for kettle heating plates, a small appliances production line, or a brazing machine, when choosing a supplier, consider asking these three questions:
1. Do they truly understand all the production process details of my product?
2. Can they provide systemic solutions that integrate equipment and production experience when complex process problems arise?
3. Is their service aimed at "solving the immediate problem" or "optimizing my long-term output and costs"?
At Davinci, our answer is always clear: we sell certainty and productivity that have been proven through our own production, and that can genuinely reduce your costs and increase efficiency. We are not only your brazing equipment supplier, but also an extension of your production team's technical expertise and a partner in your process optimization
