1.Project background

Songzhi Co., Ltd. is a leading domestic company in the field of commercial vehicle and passenger car air-conditioning. As the iteration of new energy heat pump air-conditioning products accelerates, the original air-conditioning assembly line is insufficiently automated and relies on manual inspection. It is difficult to meet the increasing vehicle-level quality standards and production capacity needs. There is an urgent need to build a fully automatic HVAC assembly assembly and testing line suitable for multiple models of products.

2. Core pain points

1. The production line layout is unreasonable, the process turnover distance is long, there is a large backlog of products in process, and the overall production efficiency is low;

2. Key tests such as NVH and electrical performance rely on manual judgment, resulting in poor consistency of results and a high risk of misjudgment or omission;

3. There are many product models, and model change adjustments are cumbersome, making it difficult to adapt to the flexible production needs of multiple varieties and small batches;

4. Production data is scattered and the quality traceability chain is incomplete, making it unable to meet the CC/SC control audit requirements of the OEM.

3. Overall solution

Based on the product categories and site conditions of Songzhi Co., Ltd., Guangke Industrial adopts a rotating ring production line layout to create a full-process automated production line for HVAC assembly that integrates assembly, inspection, and final testing. The solution integrates the concept of lean production, integrates a multi-dimensional vehicle-level inspection system and full-process data traceability, takes into account production efficiency and quality control, and supports rapid changeover of multiple models of products.

4. Solution core configuration

1. Rotating ring-shaped lean layout: The circular production line uses pallets to circulate and the workstations are compactly arranged along the ring, shortening the material turnover distance, reducing WIP, and adapting to large-volume continuous production;

2. Full-process automated assembly: covering the automatic assembly of core components such as the air inlet box, distribution box, evaporator, and heater core. Key workstations adopt an intelligent tightening system, and the torque data is fully traceable;

3. Full-dimensional inspection at the automotive level: integrated electrical performance test, NVH vibration and noise inspection, high-precision air tightness inspection, appearance visual inspection, adapted to CAN/LIN bus control, and automatic diversion of unqualified products;

4. HVAC assembly EOL final test: simulate the vehicle working conditions to complete a full-function final test before rolling off the assembly line to fully verify the product's operating performance and ensure that the factory product is stable and reliable;

5. Full-process quality traceability: RFID is bound to a single product, and assembly parameters and test results are recorded throughout the process, meeting CC/SC product special feature control and OEM supply chain traceability requirements;

6. Modular and flexible design: standardized workstation unit, only need to adjust tooling and inspection procedures when changing products, fast model change, suitable for co-line production of multi-category air conditioning assemblies.

5. Project implementation results

1. Production efficiency increased by 30%: The circular layout circulation efficiency was significantly improved, the entire line production capacity was increased by 30%, the per capita output increased, and labor costs were effectively reduced;

2. The detection accuracy rate is greatly improved: the key detection processes are fully automated, the detection misjudgment rate is reduced to less than 0.1%, and the factory yield is stable at more than 99.5%;

3. Quality control is fully up to standard: the whole process data is traceable, fully meets CC/SC control requirements, and successfully passed the OEM quality system audit;

4. Enhanced flexible production capacity: supports co-line production of multiple HVAC assemblies, shortens model changeover time by 60%, and adapts to rapid product iteration and multi-category production needs.

6. Customer value and evaluation

After the production line was put into operation, it became the core mass production line of Songzhi's new energy heat pump air-conditioning products, stably supporting the supporting production capacity of multiple vehicle projects. The product quality consistency and traceability capabilities have been highly recognized by vehicle customers, helping customers continue to consolidate their market advantages in the new energy air-conditioning track.