Address
Building A1, Runteng Industrial Park, No. 4 Xishan Road, Longteng Community, Shiyan Subdistrict, Bao'an District, Shenzhen 518000, China
Work Hours
Monday to Saturday: 09:00 – 23:00 (UTC+8)
Sunday: closed
a leading Chinese TV brand + JHIMS: 85% Faster Changeover, 30% More Throughput
85% faster lens changeover (25+ min to under 5) and 30% more throughput at a leading Chinese TV brand — two JHIMS DPS-2 multi-channel feeders, 15+ lens types.
Case Study
How a Leading Chinese TV Brand Cut Changeover Downtime by 85% and Raised Throughput 30%
85% faster lens changeover — 25+ minutes down to under 5 — and 30% more throughput for a leading Chinese TV brand, using two JHIMS DPS-2 multi-channel lens vibratory feeders across 15+ lens types.
Direct answer: A leading Chinese TV brand (name confidential) cut lens-feeder changeover downtime by 85% and raised throughput by 30% using 2 JHIMS DPS-2 lens feeders, purchased in June 2019 for TV backlight and display module lines in Huizhou. PLC profile memory recalls every lens setup in under 3 seconds — replacing 25+ minute manual retuning — while dual-frequency vibration keeps feeding stable across full shifts.
Key Takeaways
- 185% Faster Changeover
- 230% More Throughput
- 32 DPS-2 Feeders
- 4<3s Profile Recall (50 profiles)
Customer & Industry
At a glance: who the customer is, what they produce, and what drove the changeover project.
CustomerLeading Chinese TV brand (name confidential)
IndustryConsumer electronics — TV backlight & smartphone camera modules
Project LocationHuizhou, China & India
Project TypeJHIMS DPS-2 multi-channel lens vibratory feeders
Purchase Date2019-06 (2 units)
Driving RequirementCut changeover downtime in high-mix lens feeding
The customer builds TV backlight strips and display modules in more than 15 lens types, changing lens 3–5 times per shift. Each changeover took 25 minutes even when the feeder was already tuned — one to two hours of lost output a day. In high-mix production the feeder is judged by how fast the line switches lens without an engineer on the floor, not by peak speed.
Customer Background: High-Mix Lens Feeding for a TV Brand
A leading Chinese TV brand manufactures TV backlight strips and display modules with more than 15 lens types across a highly diversified product mix. Production requires 3–5 lens-type changeovers per shift, and every changeover minute directly reduces output.
Before the DPS-2 installation, each changeover meant manually retuning vibration frequency, amplitude, track width and sensors for the next lens type — a process measured in tens of minutes, repeated several times per shift, across multiple lines.
Each changeover meant retuning frequency, amplitude, track width and sensors by hand, then running the feeder until orientation was acceptable — tens of minutes, several times a shift. Amplitude also drifted as the bowls emptied, so operators adjusted mid-shift even when the product did not change. Changeovers cost output, drift cost quality, and both took operator attention.
Project Challenges: 25-Minute Changeovers
- 25+ Minute Changeovers Manual retuning of vibration frequency, amplitude, track width and sensors for each lens type.
- 75–125 Minutes of Daily Downtime Lost production from 3–5 changeovers per shift.
- Single-Frequency Drift Amplitude varied as bowls emptied, requiring constant operator adjustment during shifts.
- Operator Dependence Feeding quality depended on individual operator skill and experience.
Two mechanisms caused it. Tuning is a manual search: frequency, amplitude, track width and sensor position interact, so a workable setting is found by iteration rather than calculation. Second, single-frequency drives resonate — bowl load shifts the spring-mass behavior — so the setting that orients well in a full bowl drifts as it empties, forcing adjustments between changeovers as well.
What a changeover involved before the project and what it involves now, step by step.
| Changeover step | Before (manual retuning) | After (DPS-2) |
|---|---|---|
| Select the product | Read notes, identify lens type | Select named profile on the HMI |
| Set frequency and amplitude | Hand-tuned by iteration | Recalled in under 3 seconds |
| Set track width | Mechanical adjustment | Tool-less adjustment about 2 minutes |
| Position sensors | Adjusted and checked by trial | Recalled with the profile |
| Confirm orientation | Run until acceptable | Verification 1–2 minutes |
| Total per changeover | 25+ minutes | Under 5 minutes |
| Operator skill required | Experienced technician | Line operator |
Customer Requirements
- Changeover in Minutes Lens changeovers measured in minutes, not tens of minutes.
- Stable Feeding Consistent feed rate and low rejection across full shifts and emptying bowls.
- Multi-Lens Support 15+ lens types handled with no mechanical re-tooling.
- Low Operator Dependence Repeatable setup recall and simple operation for line staff.
The four requirements define the machine delivered. Changeover in minutes: product selection, feed-path adjustment and orientation check finish in a few minutes without specialist tools. Stable feeding: rate and rejection hold from a full bowl to an emptying one. Multi-lens support: 15+ lens types from stored settings, not re-tooling. Low operator dependence: a line operator, not an engineer, performs the change.
JHIMS Solution: DPS-2 Lens Feeder Deployment
JHIMS supplied 2 DPS-2 lens feeders, configured as multi-channel vibratory units around the customer’s 15+ lens portfolio:
- 50-Profile PLC Memory All lens types calibrated once and stored. Operators select a profile by name — all parameters recalled in under 3 seconds.
- Tool-Less Quick Change Quick-change knobs and magnetic mounts switch tracks in about 2 minutes without tools.
- Multi-Channel Concurrent Operation Idle channels are reconfigured while active channels keep feeding — no line stop for setup.
- Dual-Frequency Vibration The DPS-2 lens feeder’s patented dual-frequency control keeps amplitude stable as bowls empty, with under 0.5% rejection.
Why the Customer Chose JHIMS
- Proven Feeding Technology 0.5–1 second per lens, 3,600–7,200 UPH per channel with PLC-controlled consistency.
- Real High-Mix Capability 15+ lens types supported with 50 stored profiles — built for diversified product mixes.
- Compatibility Interface kits for Hanwha, Yamaha, JUKI, Samsung, Hitachi and Fuji pick-and-place machines.
- Validation Before Commitment A free 48-hour lens feeding test proves throughput and rejection on the customer’s own lenses.
JHIMS supplied two DPS-2 lens feeders as multi-channel vibratory units for the customer’s 15+ lens portfolio. Each lens type is calibrated once — frequency, amplitude, track width, sensor position — and stored as a named profile in the Mitsubishi FX5U PLC: up to 50 profiles, recalled in under 3 seconds. Tool-less adjustment removes the mechanical work: changeover becomes a selection, not a tuning session.
DPS-2 Lens Feeder Equipment Configuration & Specifications
From JHIMS sales records:
| Date | Item | Model | Qty |
|---|---|---|---|
| 2019-06-01 | Lens vibratory feeder | JHIMS DPS-2 | 2 |
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% |
| Changeover | Under 5 minutes — PLC profile recall & tool-less track adjustment |
| PLC & HMI | Mitsubishi FX5U + 7-inch Weintek HMI (50 profiles) |
| Power Supply | 220V AC, 50–60Hz, single phase, 0.55 KVA |
Order record: two JHIMS DPS-2 lens vibratory feeders delivered 2019-06-01, each set for the customer’s lens range. The platform handles lens diameters of 3–25 mm and covers the three-foot and four-angle reflection lenses that make up most of the portfolio. Two disc tracks are standard (expandable to ten) with two linear alignment tracks at 0.5–1 s per lens per channel. Extra lanes add capacity without re-qualifying lenses in production.
Channel capacity: one channel transfers 0.5–1 s per lens, i.e. 3,600–7,200 UPH; four channels running together reach 14,400–28,800 UPH.
Implementation: DPS-2 Lens Feeder Profile Setup & Line Integration
- Phase 1 — Lens Portfolio Assessment JHIMS engineers catalogued the customer’s 15+ lens types and feeding requirements.
- Phase 2 — Calibration & Profile Creation Each lens type was calibrated once — frequency, amplitude, track width and sensors — and stored as a named PLC profile.
- Phase 3 — Installation & Interface The DPS-2 lens feeder units were installed with brand-specific interface kits and integrated into the existing lines.
- Phase 4 — Operator Training Line staff trained to select profiles by name and perform tool-less quick changes.
- Phase 5 — Production Validation Changeover timing and throughput measured against the pre-installation baseline.
Implementation ran in three phases. First the lens portfolio was catalogued — 15+ types with their geometries, coatings and placement tolerances — defining the profiles needed. Second, each type was calibrated once and stored as a named profile, so commissioning knowledge stays in the machine, not with the engineer who tuned it. Third, the feeders were interfaced with the line and the profiles verified against the production nozzles.
Results: DPS-2 Lens Feeder Delivers 85% Faster Changeover
After the DPS-2 lens feeder installation, the customer reported the following improvements (published JHIMS case record):
| KPI | Before | After (DPS-2) | Improvement |
|---|---|---|---|
| Changeover Time | 25+ minutes | Under 5 minutes | 85% reduction |
| Daily Downtime | 75–125 minutes | Under 20 minutes | 85% reduction |
| Throughput | Baseline | +30% | Significant |
Changeover fell from 25+ minutes to under 5 — an 85% reduction — and daily downtime from 75–125 minutes to under 20, also 85%. Throughput rose 30% against the pre-project baseline. The mechanism matters more than the headline: with the profile selected rather than the machine retuned, the saving does not depend on operator experience, and amplitude is held as the bowls empty.
- Changeover 25+ minute manual retuning replaced by under-3-second profile recall.
- Capacity 75–125 minutes of daily changeover downtime recovered per line.
- Throughput 30% higher output reported after the changeover reduction.
- Consistency Dual-frequency vibration removed mid-shift amplitude drift and operator tuning.
The DPS-2 lens feeder also cut operator dependence: named profile recall and tool-less quick changes let line staff switch lens types without specialist tuning, and the same units now run both the TV backlight and smartphone camera module lines.
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DPS-2 Lens Vibratory Feeder FAQ40 real-world Q&As on the DPS-2: speed, channels, lenses, changeover and integration.Read article →Dual-Frequency vs Single-Frequency FeedingWhy dual-frequency vibration keeps amplitude stable as the bowl empties.Read article →
Manual vs Automatic SMT Lens FeedingCompare manual placement vs automatic lens feeding for high-mix production.Read article →
Lens Feeder Case Study: TV Backlight XiamenThroughput from 6,000 to 10,000 CPH and 87% fewer jams for a Xiamen TV panel leader.Read article →JHIMS Lens Feeder ROI AnalysisPayback analysis for automatic lens feeding vs manual placement.Read article →DPS-2 Troubleshooting GuideDiagnose feeding, jamming and calibration issues on the DPS-2.Read article →Frequently Asked Questions
How did the TV brand cut changeover downtime by 85%?▼
The DPS-2 stores every lens type as a PLC profile. Operators select a profile by name and all parameters — vibration frequency, amplitude, track width and sensors — are recalled in under 3 seconds, replacing 25+ minutes of manual retuning. The reported result is an 85% reduction in changeover downtime.
What equipment did the customer purchase?▼
JHIMS sales records show 2 DPS-2 lens feeders delivered to the customer in June 2019 for its TV backlight and display module lines in Huizhou, China.
How does the DPS-2 handle 15+ lens types?▼
Each lens type is calibrated once on the DPS-2 lens feeder and stored in the 50-profile PLC memory. Tool-less quick-change knobs and magnetic mounts let operators switch tracks fast, and multi-channel concurrent operation allows idle channels to be reconfigured while active channels keep running.
Why is changeover time critical in lens feeding?▼
With 3–5 lens-type changeovers per shift, every changeover minute is lost production. Cutting changeovers from 25+ minutes to under 5 minutes recovers 75–125 minutes of daily capacity — the basis of the reported 30% throughput gain.
Does the DPS-2 need manual tuning during a shift?▼
No. Patented dual-frequency vibration control keeps amplitude stable as the bowl empties, eliminating the constant operator adjustment typical of single-frequency feeders.
What support does JHIMS provide with the DPS-2?▼
Brand-specific interface kits for Hanwha, Yamaha, JUKI, Samsung, Hitachi and Fuji machines, installation, operator training, after-sales support, and a free 48-hour lens feeding test to validate throughput and rejection rate on your line.
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. Browse JHIMS machine videos on YouTube. 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 Cut Your Changeover Time?
Send your lens samples for a free 48-hour DPS-2 lens feeder test — we will validate throughput and rejection on your line, and we reply within 12 working hours (Mon–Sat, 09:00–23:00 China Standard Time, UTC+8).