1.Project background

Yinlun Co., Ltd. is a leading company in the domestic thermal management industry. With the rapid expansion of its new energy vehicle business, the order volume of valve modules continues to grow. The original production line is mainly manual assembly, and the production capacity and quality stability can no longer meet the needs of business growth. At the same time, the requirements for the control of special characteristics of vehicle-grade CC/SC are constantly increasing, and there is an urgent need to upgrade the automated production line to achieve production capacity ramping, quality control, and full-process traceability.

2. Core pain points

1. Manual assembly efficiency is low, production capacity bottlenecks are obvious, and single-shift production capacity cannot keep up with the pace of order growth;

2. Assembly accuracy relies on manual experience, product consistency is poor, defective rates fluctuate greatly, and hidden dangers in sealing performance are difficult to control;

3. The testing process is scattered, data is manually recorded and archived, quality traceability is difficult, and it cannot meet the vehicle-level CC/SC control requirements;

4. Product models iterate quickly, and the original tooling replacement cost is high and the cycle is long, making it difficult to adapt to the collinear production needs of multiple models.

3. Overall solution

Guangke Industry combines Yinlun Co., Ltd.'s valve module product characteristics, production capacity targets and factory site conditions to customize the overall solution for the valve module automated assembly line. The solution adopts a modular and flexible design concept and integrates robotic precision assembly, intelligent fixed-torque tightening, multi-dimensional performance testing and RFID full-process traceability systems to achieve full-process automated production from parts loading to final testing of finished products, fully meeting the dual needs of customers for capacity improvement and quality control.

4. Solution core configuration

1. Lean linear production line layout: adapted to the customer's existing factory site, planning 12 core workstations, with an overall cycle time of 95S, meeting the single-shift production capacity target, and leaving room for subsequent expansion;

2. Robotic precision assembly unit: The core assembly process uses industrial robots, coupled with visual positioning and correction, with stable assembly accuracy and high consistency, replacing manual core assembly stations;

3. Intelligent tightening control system: Key threaded connections adopt a fixed-torque and fixed-angle intelligent tightening system, and tightening data is uploaded and recorded in real time to ensure that the assembly force meets standards and meets quality traceability requirements;

4. Full-dimensional inspection system: integrated image visual inspection, waterside channel dry inspection, power-on performance test, and automatic diversion and rejection of unqualified products to ensure that the sealing and performance of factory products meet standards;

5. RFID full-process traceability: A single product is bound to an RFID traceability code, and assembly and inspection data are retained throughout the entire process. Quality problems can be accurately located in processes and batches, meeting vehicle regulation-level traceability requirements;

6. Production visual signage: Equipped with electronic signage in the workshop to display output, tempo, yield, and abnormal information in real time to improve on-site management efficiency.

5. Project implementation results

1. Production efficiency has been significantly improved: the overall tempo of the production line has stabilized at 95S, single-shift production capacity has increased by 35%, and the overall equipment efficiency (OEE) has stabilized at 92%, effectively alleviating production bottlenecks;

2. The quality has been greatly upgraded: the product defect rate has been reduced by 80%, the factory yield has stabilized at more than 99.5%, the sealing performance has zero batch hidden dangers, and product consistency has been significantly improved;

3. The traceability management fully meets the standards: the quality traceability efficiency is increased by 90%, the whole link data is traceable, and it fully meets the special characteristics control requirements of CC/SC products;

4. Enhanced flexible adaptation capabilities: supports the co-production of multiple types of valve products such as EXV/SOV/CV, shortens product changeover time by 60%, and adapts to rapid product iteration requirements.

6. Customer value and evaluation

After the implementation of this project, it effectively supported the capacity expansion and quality upgrade of Yinlun Co., Ltd.'s new energy valve module business. The production line has been running stably to this day, and all indicators have met and exceeded expectations, winning high recognition from customers. This project has also become a benchmark case for automation upgrades in the field of thermal management valve modules, providing a mature reference paradigm for production line upgrades of similar products.