The sanitary ware industry is increasingly shifting toward multi-variety, small-batch customized production. With a wide range of product types — faucets, showerheads, hardware accessories — traditional robot polishing lines have exposed their limitations. Launching a new product requires skilled technicians to conduct point-by-point teach programming, taking several hours per product. Changing a product line means fully disassembling and reinstalling fixtures, and debugging and calibration consume a large amount of production time, resulting in persistently low equipment utilization. Dingzhu Intelligent Manufacturing has addressed these pain points in flexible production through modular process design and standardized fixture solutions.

In programming, the traditional fully manual, from‑scratch approach has been abandoned in favor of a standardized process module database. Common processing features of sanitary ware parts — such as arcs, edges, and weld seams — are individually encapsulated. When programming a new product, users simply call up the corresponding modules and adjust key dimensional parameters. Basic programs can be shared across different grit sizes of abrasive belts; for example, the rough grinding program for 80# grit can be directly copied and the polishing angle slightly adjusted to adapt to 240# fine polishing. This improves programming efficiency by over 70%. Combined with a servo-powered force control system, polishing pressure is adjusted through parameters, eliminating repeated on‑site trial polishing and debugging.

Improving changeover efficiency also depends on fixture innovation. Dingzhu Intelligent Manufacturing promotes standardized fixture design across all product series. Multiple sanitary ware workpieces within the same product category share a single set of fixtures, so most small-batch orders require no fixture disassembly or reassembly. A high-precision locking clamp design reduces mechanical clamping errors and significantly improves clamping positioning consistency. At the same time, data across various polishing units on the production line is interconnected, allowing process programs to be copied and called across units with a single click. Changeover and debugging tasks that used to take half a day can now be completed in just a few tens of minutes.

This proven, production‑ready flexible polishing solution has helped many sanitary ware factories respond quickly to scattered custom orders, reduce the ineffective manual labor of skilled technicians, effectively increase overall equipment efficiency (OEE), and achieve flexible, high‑output automated production lines.