1.Project background

This customer is a leading independent brand car company in China. With the rapid increase in sales of new energy models, the production capacity and automation level of its own air-conditioning assembly production line can no longer match the vehicle production capacity plan. At the same time, the OEM has extremely strict requirements on the consistency, traceability and reliability of parts. It is urgent to build a high-standard, high-stability fully automatic production line for front and rear air-conditioning assemblies.

2. Core pain points

1. The original production line has a low degree of automation, high labor costs, and the production capacity cannot match the rapid growth of vehicle sales;

2. OEMs have strict quality standards and high requirements for key feature management and control, making it difficult to guarantee quality stability in manual mode;

3. Full-link traceability requirements are high, and full data traceability from parts to finished products needs to be achieved to meet the vehicle quality management system;

4. Model iteration is fast, and it is necessary to support the co-production of air-conditioning assemblies for multiple models and quickly change models to adapt to the launch of new models.

3. Overall solution

In accordance with the OEM-level quality standards, Guangke Industry has created a fully automatic line solution for customers with dual product lines of front and rear air-conditioning assemblies. It adopts a rotating ring layout and covers the entire process assembly and final testing of front and rear air-conditioning assemblies. It comprehensively benchmarks vehicle regulations and control requirements, builds a full-process quality traceability system, and takes into account the flexible production needs of multiple models.

4. Solution core configuration

1. Dual product line circular layout: each has a circular production line for the front and rear air-conditioning assemblies, with circular circulation of pallets and compact arrangement of workstations, suitable for stable mass production in large quantities;

2. Full-process automated assembly: The entire process is automated from core component loading to assembly assembly, with 100% intelligent control of key torques and automatic data upload;

3. Car-grade full-dimensional inspection: integrated electrical performance test, NVH inspection, air tightness inspection, visual appearance inspection, adapted to CAN/LIN bus, and automatic interception of unqualified products;

4. EOL full-function final test: simulate the actual vehicle installation conditions to complete the offline final test, comprehensively verify the functional performance of the air-conditioning assembly, and ensure zero defects before leaving the factory;

5. Full-link traceability system: from parts batches to finished products, the whole process of data binding and traceability meets the IATF16949 quality system and traceability requirements for the entire vehicle;

6. Flexible compatibility with multiple models: Modular design supports co-line production of air-conditioning assemblies for multiple models, fast tooling switching, and rapid implementation of new models.

5. Project implementation results

1. Stable production capacity supporting complete vehicles: the production line rhythm meets the vehicle production capacity planning, double-shift operation is stable, and effectively supports the ramp-up of model mass production;

2. Excellent quality performance: the factory yield is stable at 99.6%, there are zero batch quality problems on the line, and product consistency is highly recognized by customers;

3. The traceability system meets the standards: the entire link data is completely traceable, fully meeting the OEM quality system audit and parts traceability requirements;

4. Flexible adaptive model iteration: The mass production of air-conditioning assemblies for many new models has been successfully completed, with a short model change cycle to ensure the rapid launch of new models.

6. Customer value and evaluation

This production line is the customer's first fully autonomous production line for air-conditioning assemblies. It has been running stably since it was put into production, and all indicators have met the high standards of the OEM. It has effectively reduced dependence on external procurement, improved the independent controllability of core components, and has become a benchmark production line for internal intelligent manufacturing among car companies.