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Lens Vibrating Feeder Case Study: LED Lighting in Vietnam
Toyota-audit lens feeding case study in Vietnam: a custom DPS-2 feeder for LED lens assembly — jams eliminated, 30% faster feeding and 15% lower cost on a Samsung SLM120S line.
Case Study
How a Vietnamese LED Lighting Manufacturer Eliminated Lens Jamming and Raised Feeding Speed 30%
How a Vietnamese LED lighting manufacturer removed lens jamming from its Samsung SLM120S line with a custom JHIMS DPS-2 lens vibratory feeder — one feeder covering every lens in the portfolio, 30% faster feeding and a 15% cost reduction.
Direct answer: A Vietnamese LED lighting manufacturer (name confidential) eliminated lens jamming and raised feeding speed 30% with a custom JHIMS lens vibrating feeder integrated with its Samsung SLM120S pick-and-place line. Dual-frequency vibration (50–60 Hz), optimized wheel spokes and a precision controller removed 100% of jamming incidents and cut costs 15% by replacing multiple feeding setups with a single feeder (published JHIMS case record).
Key Takeaways
- 1100% Jams Eliminated
- 2+30% Feeding Speed
- 315% Cost Reduction
- 41 Feeder, All Lens Types
Customer & Industry
At a glance: who the customer is, what they assemble, and what drove the investment.
CustomerVietnamese LED lighting manufacturer (name confidential)
IndustryLED lighting — lens assembly
Project LocationVietnam
Project TypeCustom JHIMS lens vibrating feeder
Line IntegrationSamsung SLM120S pick-and-place (existing)
Driving RequirementEliminate jamming, raise feeding speed, one feeder for all lens types
LED lens assembly is one of the harder feeding duties in electronics manufacturing. The lenses are optically clear and often thin, so they cannot be pushed against hard tooling without risking scratches; the outline is usually a three-foot or four-angle geometry rather than a plain disc, so orientation matters in two axes rather than one.
A lighting product family also changes lens quickly, so the feeding step must support several parts without a mechanical rebuild. Add the volume requirement of a lighting line — tens of thousands of lenses a day — and manual picking becomes the bottleneck the customer set out to remove.
Customer Background: Lens Assembly Bottleneck
A Vietnamese LED lighting manufacturer struggled with inefficiencies in its lens assembly process. Before the JHIMS lens vibrating feeder was installed, lens jamming disrupted production flow, slow feeding speeds limited output, and the equipment could not accommodate the multiple lens types in the portfolio.
As LED lighting product lines diversified, the manufacturer needed a lens vibrating feeder that could handle its full lens range reliably — without jams and without separate setups for each lens type.
The cost of the old method was not only speed. Every jam stopped the pick-and-place machine and had to be cleared by hand before the line could restart, which meant one operator effectively assigned to watching the feeder for a whole shift. Slow feeding reduced output below what the assembly process could absorb.
Because each lens size and shape needed its own setup, a lens change meant stopping the line to re-adjust vibration and tooling. Those three symptoms — stops, output ceiling and lost changeover time — are the same three that appear in most lens feeding projects.
Project Challenges: Jamming, Slow Feeding, Multi-Lens Incompatibility
- Lens Jamming Lens jamming disrupted production flow and required constant operator intervention.
- Slow Feeding Speeds Feeding speeds limited line output below what the assembly process demanded.
- Multi-Lens Incompatibility Different lens sizes and shapes required different setups — no single feeder covered the portfolio.
Each of the three challenges has an engineering cause worth naming, because the fix follows from it. Jamming in a circular bowl usually comes from two lenses competing for the same track position at the same moment, which happens when part velocity varies with bowl load.
Slow feeding is the same problem from the other side: reducing amplitude to avoid jams also reduces throughput, so the line runs at the setting with fewest stoppages rather than the fastest safe rate. Multi-lens incompatibility is a tooling problem — track width, escapement geometry and sensor position are all lens-specific.
The three reported challenges mapped to their engineering cause and the design response used in this project.
| Reported challenge | Engineering cause | Design response |
|---|---|---|
| Lens jamming | Part velocity varies with bowl load; lenses compete for the same track position | Dual-frequency drives: bowl absorbs load, linear channel holds presentation |
| Constant operator intervention | Jams had to be cleared by hand before the line could restart | Jam-free transfer removes the intervention, not just the symptom |
| Slow feeding speeds | Amplitude reduced to avoid jams, so throughput ran below the line capability | Independent alignment channel allows full speed at the escapement |
| Multiple lens sizes | Track width, escapement and sensing are lens-specific | Custom routes and wheel spokes covering the whole portfolio |
| Multiple lens shapes | Three-foot and four-angle outlines need orientation in two axes | Orientation tooling verified on the customer’s own parts |
| Setup per lens type | Manual re-adjustment of vibration and tooling at each change | Stored controller settings recalled by lens type |
| Integration with existing line | Feeder had to suit an existing Samsung SLM120S head and nozzle | Standalone control cabinet, head-specific mounting bracket, no machine modification |
Customer Requirements
- Jam-Free Feeding A lens vibrating feeder delivering reliable feeding without jamming or operator intervention.
- Higher Speed Faster feeding to remove the line output bottleneck.
- Single-Feeder Flexibility One feeder covering all lens sizes and shapes in the portfolio.
- Machine Compatibility Integration with the existing Samsung SLM120S pick-and-place line.
The four requirements became the project’s acceptance criteria, which is why they are worth restating as measurable conditions rather than wishes. Jam-free operation was interpreted as no unplanned stops attributable to feeding across the burn-in run; higher speed as a feeding rate that no longer limited line output.
Single-feeder flexibility meant proven change between all the customer’s lens types without replacing tooling, and machine compatibility meant physical and electrical integration with the existing Samsung SLM120S head using the customer’s own nozzle. Writing requirements this way lets both sides agree on what has been demonstrated before the machine ships.
JHIMS Solution: Custom Lens Vibrating Bowl Feeder
JHIMS engineered a custom lens vibrating feeder for the customer’s Samsung SLM120S pick-and-place machine, leveraging advanced vibration technology:
- Dual-Frequency Vibration The lens vibrating feeder’s dual-frequency system oscillating at 50–60 Hz prevents jamming and ensures smooth part orientation.
- Optimized Wheel Spokes & Precision Controller Engineering refinements deliver 30% faster feeding.
- Custom Routes Accommodating various lens sizes and shapes — one lens vibrating feeder for the whole portfolio.
Why the Customer Chose JHIMS
- Expertise in Vibrating Feeder Systems JHIMS has engineered vibrating feeder systems since 2013.
- Proven Global Track Record Successful installations across global markets in LED and electronics assembly.
- Reliable Automation High-quality, reliable automation solutions with after-sales support.
- Custom Engineering Feeders engineered around the customer’s lens portfolio and machine line-up.
The architecture that removes the jam-versus-speed trade-off is two drives instead of one. The circular channel runs in the low-frequency band — this installation was tuned in the 50–60 Hz range — and its only job is to move lenses around the bowl and lift them onto the track; because it can be driven harder or softer without changing presentation, the bowl absorbs changes in load.
The linear channel runs at a higher frequency and holds the presentation geometry constant, so lens speed at the escapement stays the same whether the bowl is full or nearly empty. Custom routes and wheel spokes were engineered around the customer’s lens sizes, with track width and escapement set for the smallest part in the portfolio and verified upward.
Equipment Configuration: Lens Vibrating Feeder & Specifications
| Item | Model | Qty |
|---|---|---|
| Lens vibrating feeder (custom) | JHIMS DPS-2 platform | 1 |
| Pick-and-place integration | Samsung SLM120S (existing) | 1 |
From the published case record: a custom lens vibrating feeder engineered for the Samsung SLM120S line. JHIMS sales records also show 2 DPS-2 lens vibratory feeders delivered in March 2018.
Key Specifications
| Feature | Details |
|---|---|
| Lens Diameter Range | 3mm – 25mm |
| Lens Types | Inner/outer three-feet, four-angle reflection lenses |
| Number of Tracks | 2 disc tracks standard, expandable to 10; 2 linear tracks |
| Transfer Speed | 0.5–1 second per lens (single channel) |
| Rejection Rate | Under 0.5% |
| Vibration Control | Dual-frequency vibration (50–60 Hz) |
| PLC & HMI | Mitsubishi FX5U + 7-inch Weintek HMI (50 profiles) |
| Power Supply | 220V AC, 50–60Hz, single phase, 0.55 KVA |
The equipment list is deliberately short because the value of the project is in the tooling and control work rather than in a long bill of materials. One custom lens vibrating feeder on the DPS-2 platform was integrated with the customer’s existing Samsung SLM120S placement machine; the published sales record shows two DPS-2 feeders delivered for this account in March 2018.
Because the feeder is a standalone unit with its own control cabinet, nothing in the placement machine had to be modified: the mounting bracket follows the head, the pick-up platform is set to the nozzle travel, and the lens recipe lives in the feeder PLC — so the installation stays reversible if the line is reconfigured later.
Implementation: Custom Lens Vibrating Feeder Engineering & Integration
- Phase 1 — Process Analysis JHIMS engineers assessed the lens assembly process, jamming failure modes and the lens portfolio.
- Phase 2 — Custom Engineering The lens vibrating feeder’s bowl, wheel spokes, precision controller and custom routes engineered around the customer’s lens sizes.
- Phase 3 — Installation & Integration The lens vibrating feeder was installed and integrated with the Samsung SLM120S pick-and-place machine.
- Phase 4 — Production Validation Jamming eliminated, feeding speed up 30%, output boosted.
- Phase 5 — Repeat Orders The client’s repeat orders and positive feedback underscored JHIMS’s reliability.
The three phases exist to make the outcome repeatable rather than to lengthen the project. Process analysis maps the failure modes — where lenses collide, where they rotate, where the operator used to intervene — and produces the tooling brief.
Custom engineering turns that brief into bowl geometry, wheel spokes, routes and controller settings, all proven against the customer’s own lenses rather than sample parts from stock. Installation then positions the feeder at the machine, connects the line interface and verifies presentation height with the production nozzle, after which the settings are stored as a profile so a later lens change is a recall rather than a re-tuning exercise.
Video: Lens Vibrating Feeder in Production
Watch the JHIMS lens vibrating feeder feed LED lenses to a pick-and-place machine. Watch the full feeder video on YouTube.
When watching the video, three things are worth looking at because they are what the project was actually about. First, the lenses in the bowl: they should circulate continuously with no queue forming at the track entrance, which is the visual signature of a feeder that is not fighting its own load.
Second, the lenses on the linear track should arrive at the escapement already oriented, so the nozzle meets a flat, centred lens rather than correcting an angled one. Third, the pick-up rhythm: a visible change in lens spacing between a full and a nearly empty bowl is the drift a single-frequency feeder shows and this installation removed.
Results: Lens Vibrating Feeder Eliminates 100% of Jams
Reported in the published JHIMS case record for the lens vibrating feeder:
- 100% Elimination of Lens Jamming Dual-frequency vibration removed jamming incidents from the assembly process.
- 30% Increase in Feeding Speed Optimized wheel spokes and the precision controller boosted feeding speed and throughput.
- 15% Cost Reduction A single feeder for all lens types replaced multiple setups and reduced costs.
- Repeat Orders The client’s repeat orders and positive feedback underscored JHIMS’s reliability.
The three published results are connected, and reading them together explains the payback. Eliminating jamming removes unplanned stops, which restores the machine’s available time; a 30% increase in feeding speed raises output without changing the placement programme.
The 15% cost reduction comes from removing an operator from the feeding task and reducing lens scrap caused by manual handling — including scratches and dropped parts that never appear in a jam count but do appear in the material cost. For a lighting line running several shifts the saving accumulates on both sides, which is why this kind of automation usually pays back in under a year.
How Projects Like This Are Verified Before Shipment
Acceptance in feeding projects is a measured event, not a promise, and the sequence is the same for every lens type we handle. The customer sends 500–800 lenses of each type; the tooling is built and the feeder runs for 48 hours with those parts.
The run produces a report with time-series amplitude and cycle data, a breakdown of rejection causes by category, microscope inspection of lens edges after feeding, and video of the run. Measured feed rate, orientation quality and rejection are recorded in the machine birth certificate, and a 120-point quality check covers assembly and electrical work before packing.
For this customer the same sequence applied, which is why the published results can be stated as project outcomes rather than sales claims: jam-free behavior, faster feeding and reduced cost were observed on the customer’s own lenses in their own product family.
If you are evaluating a similar project, ask for the burn-in report structure first — a supplier who cannot describe how they will prove performance on your lenses before shipping is a supplier whose performance will be debated after installation instead.
What is measured before a feeder of this class ships, and where each result is recorded.
| Item | How it is verified | Recorded in |
|---|---|---|
| Feed rate | Timed cycles per channel with the customer’s lenses | Burn-in report and machine birth certificate |
| Rejection rate | Counted rejects with cause categories over a 48-hour run | Burn-in report |
| Orientation quality | Microscope inspection of lens edges after feeding | Burn-in report |
| Jam-free operation | Unplanned stops attributable to feeding, logged across the run | Burn-in report |
| Lens sample quantity | 500–800 lenses per type supplied by the customer | Sample test record |
| Amplitude stability | Time-series amplitude data across the fill range | Burn-in report |
| Assembly quality | 120-point quality check before packing | QC record |
| Profile recall | Stored settings recalled and confirmed per lens type | Machine documentation |
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How did the Vietnamese manufacturer eliminate lens jamming?▼
JHIMS engineered a custom lens vibrating feeder with dual-frequency vibration oscillating at 50–60 Hz. The dual-frequency system prevents jamming and smooths part orientation, and the published case record reports 100% elimination of lens jamming incidents.
What equipment was supplied?▼
A custom JHIMS lens vibrating feeder integrated with the customer’s Samsung SLM120S pick-and-place line. JHIMS sales records also show 2 DPS-2 lens vibratory feeders delivered in March 2018 for the same customer’s lens feeding.
How does dual-frequency vibration prevent jamming?▼
Dual-frequency vibration oscillating at 50–60 Hz keeps lenses smoothly oriented and prevents the jams typical of single-frequency bowls, while optimized wheel spokes and a precision controller deliver 30% faster feeding.
What feeding speed improvement is reported?▼
The published case record reports a 30% increase in feeding speed, boosting throughput, plus a 15% cost reduction from using a single feeder for all lens types.
Can one feeder handle multiple lens types?▼
Yes — custom routes accommodate various lens sizes and shapes, so a single feeder replaces multiple setups across the lens portfolio.
What support does JHIMS provide with the lens feeder?▼
Custom engineering for your lens portfolio and line layout, installation and integration of the lens vibrating feeder with your pick-and-place machine, operator training, and after-sales support.
What is the DPS-2 Lens Vibratory Feeder?▼
Automatic multi-channel SMT lens vibratory feeder. Feeds optical lenses (3–25mm) to P&P machines at 0.5–1 sec/lens with <0.5% rejection. Replaces 2–3 manual operators with 1 operator managing 4+ machines. Compatible with six major P&P brands. Uses Mitsubishi PLC, SMC pneumatics, Keyence sensors.
What P&P machines is it compatible with?▼
Hanwha (HM520, Decan), Yamaha (YSM20, YSM10), JUKI (RS-1, RX-7), Samsung (SM series), Hitachi (G5, SIGMA), Fuji (NXT, AIMEX). Brand-specific interface kit included. Installation: 4–8 hours with remote video guidance.
How fast? What UPH?▼
0.5–1 sec/lens/channel — 3,600–7,200 UPH/channel. 4-channel: 14,400–28,800 total UPH. 3–6× faster than manual (800–1,200 UPH). Speed consistent across full shifts via PLC control.
What is the rejection rate?▼
Below 0.5% , typical 0.2–0.4% after optimization. Compare: manual 5–15%, generic feeders 2–5%. Measured during 48-hour burn-in with your lenses. Documented in machine birth certificate.
What lens sizes and shapes?▼
3mm to 25mm diameter. Geometry: round, three-foot, four-angle, rectangular cutout. Custom track tooling available for asymmetric geometries. ±1mm placement tolerance.
How many channels?▼
Standard: 3–6 channels. Custom: up to 10. Each channel independent — own drive, sensors, jog control. All managed by one Mitsubishi FX5U PLC.
What is dual-frequency vibration?▼
JHIMS-patented: Two independent drives with separate PID controllers. Circular (50–120 Hz) for bulk movement; Direct (100–200 Hz) for precision alignment. <5% amplitude variation vs 15–30% in single-frequency.
How long is changeover?▼
Under 5 min: PLC recall <3 sec (50 profiles), tool-less adjustment ~2 min, magnetic quick-mount <1 min, verification 1–2 min. Compare: 15–30 min manual. Recovers 30–75 min/day for 3 changeovers.
Dimensions, weight, power?▼
1050×700×750mm, ~130 kg. 220V AC, 50–60Hz, single-phase, 0.55 KVA rated. Compressed air: 0.4–0.6 MPa. Noise: <65 dB(A) at 1m. Standard industrial floor loading.
What PLC and HMI?▼
Standard: Mitsubishi FX5U-32MT/ES + 7-inch Weintek HMI. 50 profiles. Option: Siemens S7-1200 + Pro-face HMI. Languages: EN/ZH/ES/VI/HI/TR. Modbus TCP for MES.
Industry 4.0 / MES?▼
Yes. Modbus TCP streams: lens count, speed, rejection, downtime, profile ID. Use: OEE dashboards, quality alerts, batch traceability (IATF/FDA), predictive maintenance. Optional: Ethernet/IP, OPC UA.
What maintenance?▼
Daily (2 min): visual inspection. Weekly (10 min): clean track, check pressure. Monthly (30 min): inspect drives, lube rails, calibrate sensors. Annual (4 hr): comprehensive PM. Manuals + cards + video guidance included.
How much?▼
Base: ~$8,000 USD . Varies by channels, options. Typical configured: $8K–$12K. Spare parts kit: $500–800. DDP available. [email protected] for quotation.
Typical ROI?▼
6–11 months payback. Labor: 67–85% fewer operators ($15K–$75K/yr). Material: rejection 5–15%→<0.5% ($30K–$75K/yr). 5-year ROI >500%. Hisense: 7-month payback, 24 units.
Payment terms?▼
Standard payment terms: 70% T/T deposit with the order, 30% T/T before shipment. Existing customers may use L/C (Letter of Credit) at sight.
Can I test with my lenses?▼
Yes — free. Send 500–800 lenses/type. 48-hour burn-in test. Report: time-series data, rejection breakdown, microscope inspection, video. Schedule live demo after. Lenses returned with machine.
Delivery time?▼
Manufacturing: 15–20 working days (std), 10 days (express). Transit: 5–7 days air, 15–35 days sea. Door-to-door: 24–62 days. DDP available. Progress updates provided.
Warranty?▼
1-year comprehensive (parts+labor). Remote diagnostics <4hr. Parts dispatch <48hr via DHL. Lifetime technical support free after warranty. Service partners: VN/IN/MX/TR. Extended 2–3yr available.
Shipping packaging?▼
Vacuum-sealed moisture barrier → ISPM-15 fumigated plywood crate → shock/tilt indicators → marine insurance. Complete docs: invoice, packing list, B/L, COO, CE, ISO, birth certificate, test report.
MOQ?▼
MOQ: 1 unit. Volume discounts at 5+, 10+, 20+. Every unit — first or fiftieth — gets identical engineering attention: sample testing, 48hr burn-in, 120-point QC, training.
How to get technical support?▼
phone (86-755) 86700443, WhatsApp, email ([email protected]), Telegram (@jinghe_tech). Engineer responds <4hr. Video-guided troubleshooting. 80%+ resolved remotely within 2hr. Service partners: VN/IN/MX/TR for on-site if needed.
Spare parts availability?▼
Dual sourcing. JHIMS dispatches from Shenzhen <48hr via DHL. OR buy locally — all components use global part numbers (Mitsubishi FX5U-32MT/ES, SMC SY5120, Keyence FS-N41N). Starter kit $500–800 covers years 1–3.
On-site installation?▼
Remote: included free — engineer guides via video (4–8hr). On-site: available ($1,500–5,000 depending on location). Operator training included with both. Materials in your language.
Service partner in my country?▼
Authorized partners: Vietnam, India, Mexico, Turkey. Other regions: remote-first model (WhatsApp video + DHL parts) resolves 80%+ without on-site dispatch. Network actively expanding.
Post-warranty failure?▼
Lifetime support continues free. Diagnosis via WhatsApp/video. Parts: buy from JHIMS (48hr dispatch) or locally (Keyence/SMC/Mitsubishi distributors). Installation guidance via video included. Never orphaned.
Certifications & docs?▼
Each unit: Machine Birth Certificate (120-pt QC, serial-numbered), 48-Hr Burn-In Report , CE Declaration , ISO 9001:2015 copy , Calibration Certificate, full export docs. Regulated industries: material certs, IQ/OQ/PQ templates.
Factory visit?▼
Yes — encouraged. 3,000 m² Shenzhen facility. Tour CNC, assembly, testing. Live demo with your lenses. Meet engineers. Visa invitation letters provided. Can’t travel? Live video tour within 24–48hr.
Warranty claims process?▼
(1) Contact → engineer <4hr. (2) Video diagnosis → 80%+ resolved remotely. (3) Parts needed → dispatched <48hr via DHL (JHIMS cost during warranty). (4) Video-guided replacement. Typical: 30min (remote fix) to 5–7 days (parts).
What industries?▼
Automotive (ADAS, LED headlamps), consumer electronics (cameras, wearables, TV backlights), medical (endoscopes, diagnostics), LED/optoelectronics, industrial automation, telecom, appliances, new energy. 2,456+ customers, 30+ countries.
Cleanroom compatible?▼
Yes — ISO Class 7 config. Sealed bearings, low-outgassing materials, ESD-safe coatings, stainless hardware, HEPA-filtered cabinet. IQ/OQ/PQ validation support. Validated for medical endoscope manufacturing (FDA/ISO 13485).
Anti-static/ESD?▼
Yes. Conductive bowl coating (10⁶–10⁹Ω per IEC 61340-5-1), static-dissipative track inserts, dedicated grounding. Recommended for LED and automotive/medical where ESD control is audited.
Expected useful life?▼
8–10+ years in 2–3 shift operation. PLC: 15+yr. Pneumatics: 8–12yr. Sensors: 5–8yr (replaceable). Rails: 12–15+yr. Structure: 20+yr. DPS-1 units (2013–2014) still in daily production.
Complex asymmetric lenses?▼
Asymmetric lenses feed at 0.7–1.0 sec/lens with 0.3–0.5% rejection — slightly slower but still dramatically better than manual (5–15%). Custom track tooling for unique geometries. Free sample testing validates your specific lenses.
Non-lens components?▼
While optimized for optical lenses, the DPS-2 can handle small rigid components (3–25mm): plastic housings, connector bodies, sensor caps, ceramic substrates. Send samples for evaluation.
Lean/sustainability?▼
Reduces: defect waste (90–97% less scrap), waiting waste (<5min changeovers), motion waste (no repetitive manual work). Energy: ~0.35 KVA typical. Primary sustainability: eliminating 90–97% of lens material waste.
Customs clearance?▼
JHIMS provides complete customs-ready docs: commercial invoice (HS 8479.89), packing list, B/L, COO (Form E/F), CE declaration, ISO 9001 copy, birth certificate. Clearance typically 1–3 days. DDP available.
Safest Incoterm?▼
DDP (Delivered Duty Paid) — JHIMS handles all shipping, insurance, export/import clearance, duties, delivery. One all-inclusive price. Next safest: CIF. Never accept EXW for first order.
Payment protection?▼
Four layers: (1) L/C at sight — strongest; (2) 70% T/T deposit + 30% balance against verified test documents before shipment; (3) Trade Assurance via Alibaba; (4) Bank account verification — beneficiary must match registered company name. Never 100% upfront.
Shipping methods/times?▼
Sea: 5–10d SE Asia, 15–20d India/ME, 20–28d Europe, 25–35d Americas. Air: 5–7d global. Express (DHL): 3–5d door-to-door (highest cost). Sea most economical for planned orders.
Trade-in/upgrade programs?▼
Trade-in credit: 10–35% of original price toward new DPS-2. Assessed on age, condition, hours, maintenance records. Returned units refurbished and resold. [email protected] for evaluation.
Ready to Automate Your Lens Feeding?
Send your lens samples for a free 48-hour lens vibrating feeder test — we will validate throughput and jam rate on your line, and we reply within 12 working hours (Mon–Sat, 09:00–23:00 China Standard Time, UTC+8).