1.Project background

Xiezhong International is a domestic professional temperature control equipment company with a wide range of energy storage liquid cooling unit product models and a high degree of customization. It mainly focuses on small and medium-sized batch orders. The original production line was mainly based on manual assembly, with cumbersome model changes and low efficiency. The assembly accuracy and sealing quality were unstable, making it difficult to match the rapidly growing order demand of the energy storage business.

2. Core pain points

1. There are many product models, small batches, slow manual changeover and adjustment, insufficient production line flexibility, and long order delivery cycle;

2. The accuracy of manual assembly is unstable, the quality of the sealing interface fluctuates greatly, and after-sales leakage complaints occur from time to time;

3. The inspection process is single, only the end of the finished product is inspected, and the discovery of problems is delayed and the cost of rework is high;

4. Production data is recorded manually, quality traceability is difficult, and it cannot meet the audit requirements of downstream energy storage customers.

3. Overall solution

Guangke Industry customizes linear flexible assembly lines according to customers' production characteristics of multiple varieties and small batches. It adopts a modular work station design, combined with visual positioning, intelligent tightening and multi-stage air tightness detection, to realize the full-process automated production of liquid cooling units from component loading to finished product unloading, taking into account assembly accuracy and model change efficiency. It is also equipped with a data traceability system to meet the quality control requirements of downstream customers.

4. Solution core configuration

1. Linear flexible layout: workstations are arranged sequentially along a straight line, with a simple structure, which facilitates phased expansion and product changeover, and is suitable for long and narrow factory sites;

2. Visual positioning precision assembly: core components are loaded using visual positioning, robots are used for precise assembly, key threaded connections are intelligently tightened, and the entire data is traceable;

3. Multi-stage air tightness testing: Air tightness testing stations are set up in different processes, and key interfaces are tested immediately after assembly. Problems can be discovered and dealt with early to reduce rework costs;

4. Modular quick changeover: standardized design of tooling fixtures. Changing products only requires switching tooling and procedures. The changeover adjustment is convenient and suitable for the alternate production of multiple models of products;

5. Full-process data traceability: a traceability code is bound to a single product, assembly parameters and inspection data are automatically recorded, and quality problems can be accurately located to meet customer supply chain audit requirements;

6. Scalable architecture: Reserves expansion interfaces for later processes, and can add inspection and aging stations as business grows to adapt to capacity upgrades.

5. Project implementation results

1. Increase production efficiency by 35%: Automation of core processes replaces labor, single-shift production capacity increases by 35%, and order delivery cycles are significantly shortened;

2. The sealing quality has been greatly improved: multi-stage air tightness testing is implemented at all levels, the finished product sealing yield has been increased to 99.3%, and after-sales leakage complaints have been significantly reduced;

3. Model changeover efficiency is greatly optimized: product changeover time is shortened by 70%, small and medium-sized batch customization orders can be quickly responded to, and market adaptability is enhanced;

4. The traceability system is comprehensively improved: production data is automatically retained, the entire chain is traceable, and it has successfully passed the quality system audits of many leading energy storage customers.

6. Customer value and evaluation

After the flexible assembly line was put into production, it effectively solved the efficiency and quality pain points of Xiezhong International's multi-variety production, supported the rapid growth of the energy storage business without adding a lot of manpower, and at the same time improved product quality and traceability, helping customers successfully enter the supply chain systems of more leading energy storage companies.