To optimize the production flow efficiency in the workshop, Dongguan Shangsheng Acrylic Products Co., Ltd. has completed the zoning renovation of the raw material warehouse. Various acrylic sheets, adhesives, printing consumables, and hardware accessories are now categorized into separate storage areas, with labeled shelves installed. This significantly reduces the time workers spend collecting materials and alleviates production preparation pressure during peak seasons. The company uses a wide variety of raw materials in its daily processing, ranging from 1mm ultra-thin transparent sheets, thick industrial sheets, colored frosted sheets, and semi-transparent two-color sheets, to bonding adhesives, UV inks, installation hardware, and polishing consumables. There are over 30 types of materials, which were previously all mixed together. Workers had to search for a long time to find the right materials, delaying processing progress, and occasionally they would pick up the wrong thickness or color of sheets, leading to processing errors and material waste.
After the renovation, the warehouse is divided into three major sections: sheet storage, consumable storage, and hardware accessories. The sheet storage area is further subdivided into transparent acrylic, frosted sheets, colored sheets, and a recycled edge and corner material area. Each type of sheet is stacked by thickness and size, with clear labels on the shelves indicating specifications and stock quantities. Workers can quickly locate the corresponding raw materials based on their order requirements. Adhesives, UV inks, and other consumables are placed in a separate light-proof storage room to prevent deterioration due to sunlight exposure. Screws, clips, brackets, and other hardware accessories are stored in labeled boxes, categorized by specifications, making it unnecessary to search individually for small-order materials.
The warehouse also establishes a stock ledger, with daily checks on the remaining quantities of sheets and consumables. Materials with low stock levels are communicated with suppliers in advance to avoid raw material shortages that could halt workshop operations. The edge and corner material area is separately planned, with categorized storage for leftover sheets of various sizes. Small scraps are used for prototyping and small component processing, maximizing material utilization and reducing waste, thereby controlling production costs.
The material collection process has also been simplified. Workshop operators present production orders to the warehouse, where staff quickly match the required materials based on the labels. Previously, the average time for a single material collection was over ten minutes, but after the renovation, it has been reduced to under three minutes. This saves a significant amount of production waiting time daily, allowing the workshop to process an additional batch of orders under the same staffing conditions. At the same time, the likelihood of picking up the wrong sheets or consumables has decreased, and the number of scrapped sheets due to incorrect material matching has dropped significantly, saving on raw material costs.
The warehouse renovation involved the installation of shelves, categorized storage tools, and signage, all funded by the company. There has been no increase in the pricing for acrylic custom processing, and customers continue to receive stable and affordable pricing. The renovation was completed during the peak season for cultural and creative product inventory preparation in the stores. The workshop's raw material supply has been smooth, with improved order processing speed and stable and controllable delivery times for large-volume custom orders.
The company plans to introduce a simple electronic inventory registration method in the future to real-time synchronize inventory of various types of plate materials, predict raw material consumption rates in advance, further improve warehouse management, optimize overall production efficiency from the raw material flow link, and respond more quickly to customer customization needs.
CN