🇮🇩 Indonesian Client Story: From Hour-Long Changeovers to 10-Minute Turnarounds
Client Background & Initial Challenges
In 2023, we partnered with a manufacturing client based in Indonesia who specializes in producing PVC luggage tags, card holders, keychains, and other soft rubber accessories. Their primary market is overseas e-commerce platforms, which means handling high-volume, multi-SKU orders under tight delivery timelines.
Despite a strong customer base, they faced increasing production delays caused by frequent product changeovers. Every time a new design needed to be produced, their team had to stop the line, manually adjust parameters, and often go through trial-and-error just to ensure proper alignment and dispensing accuracy. Each setup could take 45 minutes to over an hour, severely impacting productivity and causing customer complaints.
Our Solution: A Smarter, More Flexible Workflow
To solve these issues, we designed a highly adaptable and AI-driven production line, specifically tailored for small-batch, multi-design workflows:
🔹 2 AI-Powered Soft Rubber Dispensing Machines
One-click path generation: Operators can now import vector files (e.g., .AI or .DXF) and the system auto-generates the dispensing path based on color zones and edge boundaries.
Automatic height detection: This feature accounts for uneven mold surfaces or reused base plates, ensuring consistent resin output and accurate detailing.
🔹 1 Smart Three-Station Oven
This compact yet powerful oven allows pre-heating, curing, and post-curing to happen in parallel, reducing total baking time per batch.
Each station can be independently programmed to suit different product requirements, helping the client run different SKUs without interruption.
Impact & Results
After installation and a brief training period, the client saw immediate improvements in both production flexibility and order reliability:
✅ Product changeover time dropped from 60 minutes to under 10 minutes
✅ Overall throughput increased by 38% in the first month
✅ Rework and reject rates due to height errors dropped by over 70%
✅ The team was able to take on more short-term promotional orders with confidence
Client Testimonial
“Previously, changing a product took almost an hour. Now it’s done in 10 minutes — no trial-and-error, no delays. Meeting orders is no longer a painful experience. We feel like our factory is finally future-ready.”
Conclusion
This case highlights the value of combining AI automation, vision-driven adjustments, and multi-station workflow design in real-world manufacturing. For factories with diverse product lines and fast turnaround needs, having flexible, intelligent systems is not just helpful — it's a game changer.
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