1.

0 INTRODUCTION

Figure 1.0: Company name

Figure 1.0 shows the Chinese name of Yangzhou Shuguang Toothbrush Factory. This company
is selected as the manufacturing company to study for this report. The background, product,
manufacturing process and product system of the company are discussed in this report.
2.0 THE BACKGROUND OF THE COMPANY AND ITS PRODUCT

Figure 2.1: The Company

Yangzhou Shuguang Toothbrush Factory is one of the professional manufacturers of oral
hygiene products in China, was founded in 1974 and mainly engages in manufacture and export
toothbrush series, and other oral hygiene products. They are very strong in manual toothbrushes
for adult & kids. Their toothbrushes brand "Dr. good" are certified by ISO9001, FDA and SGS.

Figure 2.2
Figure 2.2 is certification documentary of ISO9001, FIDA and SGS for Yangzhou Shuguang
Toothbrush Factory. They have their own mold workshop, which already successfully developed
customized design for many customers.

Figure 2.3: Factory view

Figure 2.3 show the view in inside of the factory. The area of factory is 26,000 square meters and
equipped with advanced machines and lines, which can produce 15 million toothbrushes every
month.

Figure 2.4: Product

Yangzhou Shuguang Toothbrush Factory has over 300 design of toothbrush. They mainly
produce tongue cleaner, adult toothbrush, children toothbrush, travel toothbrush, electric
toothbrush, dental floss, protective cap and others. Figure 2.4 show the toothbrush made by Yang
Shuguang Toothbrush Factory.
3.0 THE MANUFACTURING PROCESS & LAYOUT OF THE FACTORY

Figure 3.1: Flow chart of manufacturing toothbrush

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Figure 3.1 shows the manufacturing process of toothbrush. Basically, manufacturing process
consist of two basic types process, they are processing operation and assembly operation. The
manufacturing of toothbrush process involves both operations, processing process for handle and
bristle and assembly operation for joining them to form a toothbrush as shown in figure 3.2.

Figure 3.2
From figure 3.1, the raw material plastic and nylon would be processing into handle and bristles
separately by Injection Molding Machine and bristle cutting machine. Then, bristles would tuft
to the core on handle head by tufting machine, the bottom of the bristles is attached by a metal
staples to make the bristles easy to positioning to the cores. However, the toothbrush still
considered as semi-product. The toothbrush would passes through a trimming machine which
slices the bristles to the correct length and shape for the particular design. Then, the product
would undergo quality checking and finally packing by packing machine.

Figure 3.3
The manufacturing process of toothbrush in Yangzhou Shuguang Toothbrush Factory can be
classified as shown in figure 3.3.The cutting and trimming process is done on nylon to get
bristles of toothbrush and correct length and shape for the particular design. Plastic injection
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molding is done to obtain shape of handle and hot stamping process is print color on the
toothbrush. Furthermore, the turting and filling process is positioning the bristles to cores of
handle
For cutting process, the Automatic material bristle cutter as shown in figure 3.4 is used to cut the
nylon material into bristle. This machine is made of stainless steel and meet requirement
hygienic production environment. It feed air-pressure cutting, transparent & safety protection
cover and special sharp cutting edge. It also contains cabinets for storing nylon (material bristle),
in which the dehumidifier is installed, which can get rid of the moisture inside nylon into the
water storage tank to stay nylon perfect under the proper drying reading. Nylon without moisture
can have each tuft of brush inserted averagely on each hole to keep the tufting process smooth &
precise, which is a requisite for making the top quality toothbrushes.

Figure 3.4
For trimming process, the Automatic bristle trimming & end-rounding machine is used to trim
the bristle on toothbrush to correct size and make the edge of bristle to become rounded as
shown in figure 3.5.

Figure 3.5
For plastic injection molding, the Plastic injection molding machine is used to inject 8~12pcs
(depends on what kind of toothbrush, usually it's 8 cavities per mold) of single color toothbrush
handles per 30~40 second per shot. After the product solidify, the toothbrush holes after will be
quite accurate & precise during tufting. The machine is shown as figure 3.6.

Figure 3.6
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For hot stamping process, the air pressure hot stamping machine is used to print color on the
toothbrush handle. The picture of air pressure hot stamping machine is shown as figure 3.7.

Figure 3.7
For tufting or filling process, the automatic 2-colour toothbrush tufting machine is used to filling
the bristle to the core of handle. The machine is shown as figure 3.8. The machine would attach
the fiat brass wire bottom of selected bristles and then insert the bristles into the core of handle
with super speed. This process is considered as assembly process because involve joining
process.

Figure 3.8
The arrangement of the machinery of toothbrush is shown as the figure below:

Figure 3.9: 2D Factory layout

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4.0 THE LIST OF PRODUCTS

The products manufactured by Yangzhou Shuguang Toothbrush Factory are tongue cleaner,
adult toothbrush, children's toothbrush, travel toothbrush, electric toothbrush, dental floss and
protective cap.
Product

Detail
Humanized design tongue cleaner on head
backside can be applied easily for removing
tongue surface bacteria, which can make oral
more higiene.
Gum massaging bristles gently massage and
stimulate gums and help clean along the gum
line.
It has 38 different designs.

1) Tongue cleaner

2) Adult toothbrush

Non-slip universal thumb grip gives user

exceptional control over brush strokes.
All the bristles ends have been grounded to
remove the acute angels. All ends are with
round surface. It protects the gum from being
hurted, effectively cleans the teeth, defends
periodontal disease.
Bristles type: Sharp soft bristles or Nylon 610
or or Dupont Tynex . All the bristles end
have been grounded to remove the acute
angels. All ends are with round surface.
It has 168 different designs.

3) Childrens toothbrush

Cute animal shaped handle is attractive to

kids & makes children interested in brushing
their teeth regularly.
It has 44 different designs.

4) Travel toothbrush

It has 5 different designs.

It can be packed according to the user
demand.

It has 2 different designs.

5) Electric toothbrush

Electric Toothbrush will give users superior

clean with 50% more brush movements than
usual.

Dental floss is a cord of thin filaments used to

remove food and dental plaque from between
texeth in areas a toothbrush is unable to reach.

6) Dental floss

It has 6 different designs.

Protective cap is a cap used to protect the

toothbrush form polluted.

7) Protective cap

It has 9 different designs.

5.0 THE PRODUCTION SYSTEM

Production system is people, equipment, and procedures used for the combination of materials
and processes that constitute a company manufacturing operations. A manufacturing company
must have systems and procedures to accomplish its type of production.
There are two categories of production systems which is production facilities and manufacturing
system. The production facilities include the factory, production equipment, material handling
system. Manufacturing systems refer to logical groupings of equipment usually organized in a
company according to their quantity of production.
Yangzhou Shuguang Toothbrush Factory consists of warehouse for finished products and
warehouse for raw material where they act as material handling system. Furthermore, Yangzhou
Shuguang Toothbrush Factory also consists of quality investigate department and packaging
department to quality check the product before go into the packaging department to package the
final product.
Yangzhou Shuguang Toothbrush Factory also consists of equipment to manufacture toothbrush.
They are automatic 2-colour toothbrush tufting machines, automatic material bristle cutter
&water seperator machine, auto bristle trimming and end-rounding machine, semi-auto bristle
trimming machine, air-pressure hot stamping machine, injection molding machine &related
equipments.
Based on the quantity of production of Yangzhou Shuguang Toothbrush Factory, the company
with high production or mass production because the production quantity is more than
1,000,000.So, which mean the Yangzhou Shuguang Toothbrush Factory has high demand for
toothbrush and the manufacturing system dedicated to the production of toothbrush.
Yangzhou Shuguang Toothbrush Factory will fall under category flow line production because it
has multiple machines or workstations and it is arrange in sequence this can inspect on figure 3.2.
Furthermore the product, toothbrush is complex product because it required multiple processing.
The work units are physically moved through the sequence to complete the product. The
workstations and equipment are designed specifically for the toothbrush to maximize efficiency..
The figure 4.0 shows the one of the workstation, when the semi-product finish will be collected
and send to other workstation to continue the process.

Figure 4.0
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6.0 REFERENCE
1) http://www.chinabboss.com/tongue_cleaner.php
2) http://www.sunrisebrush.com/

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