Project Background
Our client is a leading domestic automotive parts group that primarily manufactures body structural components and chassis welding assemblies. The original production lines relied heavily on manual welding, which exposed three major pain points: difficulty recruiting skilled welders, inconsistent weld quality, and constrained takt times. The goal was to complete an intelligent upgrade without interrupting production.
Our Solution
Built around the concept of “replacing manual labor with robots and managing production digitally,” we delivered a turnkey solution covering process simulation, line integration, and MES interfacing:
- Deployed 12 six-axis robotic welding workstations, complete with positioners and automatic torch-cleaning & wire-trimming units
- Integrated a laser-vision seam-finding system that automatically compensates for workpiece deviations of up to ±3 mm
- Developed a digital monitoring platform for the welding process, capturing parameters such as current, voltage, and wire feed speed in real time
- Connected to the client’s MES and quality traceability systems to deliver weld-by-weld, full-lifecycle traceability
Project Results
- Line utilization rose from 68% to 92%, and annual capacity increased by 55%
- First-pass weld quality reached 99.5%, cutting rework costs by 80%
- Per-shift staffing was reduced from 28 to 6 operators, with the investment fully recovered within two years
- Welding parameters are 100% digitally archived, and the line passed the IATF 16949 system audit
“We were deeply impressed by the expertise and delivery capability of the Huayuan Intelligent Manufacturing team. The line passed final acceptance on the first attempt and has been running stably ever since.” — Head of the client’s Manufacturing Center