Keyto Factory has a total of three department: Valve and Pump Assembly, Specialized Processing, and Mold Injection Molding. All three manufacturing dept. are located in the Fu Yong Street area of Bao'an District, Shenzhen. In order to provide a direct understanding of Keyto Factory, we will divide the information into three videos, each explaining the real situation of the three major factories.
Now we will introduce Keyto's main product line, which is our valve and Pump Manufacturing Base. The base covers a total large area and adopts an integrated production model that includes assembly, inspection, and packaging. We have implemented the fourth-generation "Cell Line" lean production layout, ensuring a clean and organized environment. Each production line is based on a "value stream map" and consists of flexible and standardized operational unit matrices based on process characteristics.
The entire layout follows the 8S standardization management, adheres to the "one-piece flow" principle for control, employs "pull-type kanban" for special processes, and has implemented an "andon system" for orderly operations. Labor intensity levels are defined according to M3 standards to ensure that the workforce remains focused.
On-site, we have three micro-level high-precision assembly production lines and several FFU units in a 10,000-grade dust-free workshop. The environment is maintained at a temperature of 18-26°C and a humidity of 75% throughout the year.
Through the use of an ERP platform and a "Warehouse Control Procedure," we efficiently manage the accounting, batch control, temperature and humidity monitoring, inventory turnover, first-in-first-out, and expiration dates of finished products and materials.
Furthermore, our factory has fully equipped fire safety software and hardware facilities, as well as a management system that complies with national fire safety requirements. Our excellent awareness of safety prevention has earned us the title of "Fire Safety Benchmark Enterprise" awarded by the community.
During the product assembly process, we have implemented flexible and standardized measures to ensure ease of use, standardization, error prevention, and simplicity. These measures include a combination of manual and automated processes, high-precision equipment, tools, jigs, as well as the use of operation guides, production flow charts, process flow cards, PFMEA, and IPQC inspection sheets for process control.
In terms of personnel, we have a total of approximately 240 on-site employees, with a management team consisting of experienced professionals with a background in Japanese and Taiwanese enterprises and 15 years of production management experience. The ratio of testing personnel is no less than 50% of the total workforce, with at least 30% being technicians at or above T3 level. The ratio of operators is no less than 40% of the total workforce, and the proportion of fully skilled workers is no less than 10%, all of whom are technicians at or above T4 level.
You may be curious about the many empty spaces on the production line. Is it due to a lack of personnel? In fact, the reason behind this is that most of Keyto's main customers come from industries such as healthcare and environmental protection, which are characterized by multiple varieties, small batch sizes, and customization. To quickly respond to orders and meet the diverse needs of customers in terms of multiple varieties, small batch sizes, and customization, we have developed our own approach.
In terms of personnel management, we have long adopted a unique "Y-shaped" dual promotion channel and a hierarchical system, clearly defining job functions. We have also established a comprehensive multi-skilled worker education and training system, as well as a mentorship system, enabling team members to rapidly enhance their abilities and integrate into a learning-oriented team atmosphere. Internally, we have established a dedicated lean production improvement team to continuously promote lean production improvement activities.
Therefore, when you see many empty spaces on the production line, it is actually due to a work mode where people move while equipment remains stationary. In this flexible workflow, products, equipment, and materials are not restricted, providing high adaptability. Thanks to long-term systematic training, employees can adapt to the use of equipment and materials on each line according to standardized procedures, enabling diverse production operations.
It is worth mentioning that our approach differs from traditional manufacturing methods, as it ensures reliable and efficient human-machine collaboration, achieving rapid matching of manpower and machinery to support a wide range of customer needs. The main advantages of this approach are flexibility, speed, and standardization through the integration of human-machine automated processes.
Aside from the visible details mentioned above, we also have some hidden and crucial technologies. We have implemented a Manufacturing Execution System (MES) based on Keyto's production model. This system enables barcode-based production process control, process traceability, and delivery management on a fully integrated platform.
Speaking of MES systems, you might be unfamiliar with them. To give an analogy, if manufacturing equipment is the hardware of a factory, MES is essentially the factory's core operating system, ultimately enhancing its competitiveness.
So, how does Keyto's MES system operate in the factory?
Taking our products as an example, each product has dozens or even hundreds of processes, with each process having multiple requirements for qualified parameters. For instance, a valve may require physical parameters such as pressure values and temperature/humidity requirements, dimensional specifications, chemical resistance, corrosion resistance, and automation and safety of processing equipment. Real-time monitoring and maintenance of these parameters require the collaborative efforts of numerous engineers, operators, and testers to ensure stable yields.
In traditional component production, to ensure product yields and prevent adverse effects on subsequent processes, buffer time is allocated for yield verification testing at each process. When these testing buffers are combined, it lengthens the overall production cycle.
By leveraging the MES system, Keyto has achieved real-time online monitoring and automatic adjustments throughout the entire process. Our automation, informatization, and instrumentation upgrades are mainly focused on product testing, aimed at improving quality control capabilities. The imported measurement systems meet the standards of GR&R (repeatability and reproducibility of measurement systems) and CMK (equipment capability index).
Operators are responsible only for loading and unloading materials and scanning barcodes, while they are not involved in the decision-making process of the entire testing system. The reliability and consistency of the testing system fully meet the quality control requirements of downstream customers, eliminating the need for repetitive verification time. With this approach, the time required for a product, from raw material to assembly, testing, and delivery, can be significantly reduced, resulting in several times the output of traditional processing methods and improving the yield and overall efficiency of the product.
Additionally, in combination with the ERP system, we can achieve process traceability and flow control of key processes from material receipt to finished product assembly, testing, packaging, and delivery. This integration allows for real-time tracking of order delivery progress and detailed data, providing an information platform for delivery management.
Apart from the aforementioned points, it should be added that the on-site processes and environment comply with ISO 9001/13485/14001 system management requirements and have obtained system certification.