Against the market norm of “small-batch orders, personalized demands, and short delivery cycles,” small and medium-sized manufacturing enterprises (SMEs) are generally trapped in the predicament of “slow changeover, high costs, and low fault tolerance.” Specialized fixtures in sewing workshops cannot adapt to multiple clothing styles, fixed molds in injection molding factories struggle to undertake customized orders, and the single-process setup of silicone production lines restricts product innovation—all these problems stem from the “rigid structure” of traditional processes. Process modularization, by decomposing production processes into independently combinable units, enables enterprises to achieve “multi-product manufacturing with one base, rapid model changeover, and on-demand adjustment,” becoming a key path for SMEs to break through the bottleneck of market responsiveness.
I. Core Values of Process Modularization: Three Tailored Advantages for SMEs
Process modularization is not an exclusive technology for large enterprises, but a “flexible transformation solution” for SMEs based on existing resources. Its core values are precisely aligned with the production characteristics of SMEs:
| Advantage Dimension | Specific Performance | Practical Significance for SMEs |
| Efficient Changeover | Modular combined changeover reduces core process switching time by over 80% | Capable of undertaking multiple types of small orders simultaneously, avoiding downtime waiting for single orders |
| Controllable Costs | Reusable general modules reduce customized costs of special modules by 60% | No need for new production lines; transformation can be achieved with existing equipment |
| High Fault Tolerance | Single module failure does not affect overall production, enabling quick replacement and repair | Reduces the risk of order delays caused by equipment failures |
II. Four Core Principles of Process Modularization Design
When implementing process modularization, SMEs should avoid the tendency of “pursuing comprehensiveness without focus” and formulate plans around the principles of “practicality, universality, low cost, and ease of operation.” The specific principles are as follows:
- Precise Function Decomposition: Decompose processes into “core processes + auxiliary processes.” Core processes (such as overlocking in sewing and molding in injection molding) are made into general modules, while auxiliary processes (such as embroidery in sewing and coloring in injection molding) are made into replaceable special modules.
- Standardized Interfaces: Unify connection methods between modules (such as fixture interfaces and circuit interfaces) to ensure free combination of different modules and avoid compatibility issues caused by “one interface per module.”
- Cost Priority: Give priority to transforming existing equipment for general modules; select lightweight materials for special modules (such as using aluminum alloy instead of steel for injection molds) to control the cost of a single module within RMB 10,000.
- Ease of Operation: Module changeover does not require professional technicians and can be completed by front-line workers after simple training. For example, using snap-on design instead of bolt fixing to shorten installation time.
III. Process-Specific Modularization Implementation Plans (with Tools and Cases)
Based on the production characteristics of the three core processes (sewing, injection molding, and silicone processing) and the actual resources of SMEs, the following directly implementable modularization plans are designed:
3.1 Sewing Process: “General Host + Quick-Change Accessories” Module System
Core Module Division:
- General Modules: Intelligent sewing machine host (retaining basic sewing functions and supporting parameter memory), general fabric feeding mechanism.
- Special Modules: Quick-change presser feet (adapting to thick fabrics, thin fabrics, and elastic fabrics respectively), detachable embroidery heads, customized cutting templates.
Implementation Tools: Snap-on presser feet (changeover time < 5 minutes), magnetic cutting templates (adsorb directly without fixing), parameter memory cards (storing sewing parameters for different fabrics).
Case Reference: A small clothing factory transformed traditional sewing machines into modular equipment. The general host retains basic sewing functions, equipped with 3 sets of special presser feet and 2 sets of embroidery heads, enabling quick changeover for producing three types of products: jeans, T-shirts, and hoodies. The changeover time was shortened from 2 hours to 15 minutes, and the profit margin of small-batch orders (50-200 units) increased by 30%.
3.2 Injection Molding Process: “General Mold Base + Quick-Change Cavity” Module System
Core Module Division:
- General Modules: Standardized mold base (compatible with different cavities, including cooling system and ejection mechanism), general injection machine nozzle.
- Special Modules: Quick-change cavities (customized by product specifications, made of aluminum alloy), adjustable sprue bushings.
Implementation Tools: Hydraulic quick-change device (cavity changeover time < 30 minutes), standardized mold base interface (compatible with most small and medium injection machines), lightweight cavities (cost per set < RMB 8,000).
Case Reference: A plastic parts factory serving smart home brands adopted the “general mold base + 3 sets of quick-change cavities” plan to produce power supply housings of different specifications. The cavity changeover only takes 25 minutes, and the cost of a single cavity is 70% lower than that of traditional steel molds. It successfully undertook customized orders of 500 units per style, and the order delivery cycle was shortened from 15 days to 7 days.
3.3 Silicone Process: “General Mixing + Zoned Molding” Module System
Core Module Division:
- General Modules: Intelligent mixer (adjustable ratio, memorizing different formula parameters), constant temperature heating channel.
- Special Modules: Quick-change molding molds (customized by product shape, made of flexible silicone), replaceable demolding mechanisms.
Implementation Tools: Magnetic molding molds (changeover time < 10 minutes), formula memory panel (one-click call of mixing parameters for different products), small demolding robots (replacing manual work, compatible with multi-specification molds).
Case Reference: A silicone products factory producing mobile phone buttons and bracelet accessories realized modular transformation. The general mixer, combined with 4 sets of special molds, can achieve quick changeover for 6 types of products. The accuracy rate of mixing parameter call is 100%, the batch unqualified rate dropped from 8% to 1.5%, and the number of small-batch orders undertaken per month increased from 12 to 35.
IV. Five-Step Implementation Process for Process Modularization
SMEs can promote modular transformation in an orderly manner according to the following steps to reduce trial-and-error risks:
- Order Analysis (1 Week): Collect order data from the past 3 months, screen out the 3-5 types of products with the highest proportion, and identify core production processes.
- Module Design (2 Weeks): Cooperate with equipment suppliers to design general modules for core processes and special modules for differentiated needs, and clarify interface standards.
- Small-Scale Pilot (1 Month): Select 1 piece of equipment for modular transformation, trial-produce 2-3 types of small orders, and verify changeover efficiency and cost control effects.
- Optimization and Promotion (2 Weeks): Adjust module design based on pilot problems (such as simplifying changeover processes and optimizing interface stability), then promote to 2-3 core equipment.
- Standardized Management (Long-Term): Formulate module operation manuals and maintenance processes, establish module inventory ledgers, and ensure on-demand allocation of special modules.
The key to process modularization for SMEs is not to pursue “technical perfection” but to “meet actual needs.” Starting with the most frequently undertaken orders, complete the modular transformation of core processes with minimal cost, achieve “small-scale breakthroughs” first, and then gradually expand the scope of upgrading. Only in this way can SMEs flexibly respond to the market while ensuring stable production and controllable costs.