Factory Automation Upgrade

Project Background

The client is a large automotive parts manufacturer specializing in the production of precision components such as engine blocks and transmission housings. With increasing market demand, the factory faced the following challenges:

1. Low Production Efficiency: Traditional production lines relied heavily on manual operations, resulting in slow cycle times and insufficient capacity to meet order demands.
2. Unstable Product Quality: High error rates in manual inspections led to a product qualification rate of only 92%.
3. Cost Pressure: Rising labor costs and high employee turnover increased training expenses.
4. Outdated Data Management: Production data was recorded manually, making real-time monitoring and analysis impossible.

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Solution

We provided the client with a comprehensive automation upgrade and transformation solution, covering hardware upgrades, software integration, and data analytics:

1. Automated Production Line Transformation
   • Deployed 20 industrial robots (welding, handling, assembly) to replace manual labor in high-intensity, high-precision tasks.
   • Added 5 flexible production lines to support multi-variety, small-batch production modes.
   • Installed an Automated Storage and Retrieval System (AS/RS) for automatic material handling and distribution.
2. Intelligent Inspection System
   • Introduced machine vision inspection equipment to conduct 100% full inspection of critical dimensions and surface defects, with an accuracy of ±0.01mm.
   • Integrated AI algorithms to analyze inspection data in real time and automatically adjust process parameters.
3. Industrial Internet of Things (IIoT) Platform
   • Deployed 500+ sensors to collect real-time data on equipment status, energy consumption, and production progress.
   • Established a Manufacturing Execution System (MES) to digitize production planning, equipment maintenance, and quality traceability.
4. Energy Management System
   • Installed smart meters and energy monitoring modules to optimize equipment operation modes, reducing energy consumption by 15%.

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Implementation Results

1. Improved Production Efficiency:
   • Production cycle time reduced from 120 seconds/unit to 80 seconds/unit, increasing capacity by 35%.
   • Automation rate of production lines reached 85%, reducing 30 manual operation positions.
2. Enhanced Product Quality:
   • Product qualification rate increased from 92% to 98.5%, and customer complaints decreased by 60%.
3. Cost Savings:
   • Labor costs reduced by 25%, saving approximately ¥5 million annually.
   • Equipment failure rate decreased by 40%, and maintenance costs reduced by 20%.
4. Data-Driven Decision Making:
   • Achieved real-time visualization of production data, enabling management to monitor production status via mobile devices.
   • Optimized production planning based on data analysis, improving on-time order delivery rate to 95%.