Assembly

Assembly service is the comprehensive capability of our “integrated processing” system.

1. How We Do Assembly for Finish Product?

Our one-stop smart manufacturing solution combines precision tooling and injection molding, precision hardware processing, manufacturing, procurement, logistics, automation operated by our highly qualified staff who are well versed in precision manufacturing and years of manufacturing engineering technology to create irreplaceable value for our customers.

We stand on the quality core value of “Quality is Developed” and believe that “Quality Consistency” is manufactured, and bring the quality consciousness of all employees into every process of manufacturing quality, from discrete materials to product integration and even every detail of logistics. High quality standards have been established and are being effectively implemented. Our manufacturing capabilities are backed by state-of-the-art facilities and management, utilizing a leading-edge flexible production model that can precisely match individual needs between different customer orders.

Our production facilities, industrial talent and extensive experience enable us to provide diverse and flexible manufacturing services to assist our customers in winning the market. We understand that the key to success as a manufacturing service provider is to bring products to market quickly, provide a cost effective production plan and superior quality, which is the core value of our assembly services.

2. How To Prevent Errors In Finished Product Assembly?

The error prevention of finished assembly parts is not only the responsibility of the production department, but also needs to be planned in the product R & D stage. It is necessary to
minimize the possibility of wrong assembly in the process of final assembly production and formulate error prevention management measures. In the manufacturing process, we should build a
rigorous error prevention management system and strictly implement it.

Part 1 error proofing strategy in design stage

Manufacturability design is adopted at the design source. Taking measures from the design to make the product have automatic error prevention ability can fundamentally prevent the opportunity
of error. This error prevention method is 100% non failure, and it is the safest and economic error prevention measure. The error prevention measures of parts in the design stage are as
follows:

(1) Minimization of differential parts

In order to shorten the R & D cycle, reduce the R & D cost and ensure the R & D quality, the principles of platform and modularization should be followed in the development of new models,
that is, new models should try to use the same platform parts, reduce the differences of parts between models, eliminate the possibility of wrong assembly from the root, and reduce the
management cost and logistics cost of the production site. The sharing of parts can also be realized in the same model. In order to prevent the wrong connection of washer motor connector and
avoid the disorder of washer function, integrate the front and rear washer motor connector ports from two into one to avoid errors.

Figure 1 no error proofing

Figure 2 color error proofing of washer connector

Figure 3 error proof structure of washer connector

Figure 4 double motor is changed to single motor, and the models used are universal

(2) Parts exchange

In the process of model development, it is inevitable that the parts of new models cannot be shared. For example, there are interference parts on the new model of the used parts. At this time, it is necessary to modify and avoid on the basis of the original parts to adapt to the new model, and its assembly attributes (positioning mode, assembly process, etc.) have not changed. After the development of new parts is completed, if the new parts are assembled on the existing models without performance, quality and other related problems, the original parts can be replaced with new parts to reduce the difference of parts. For example, the length of the fastener of the underbody cover of model a is 20mm, and the length of the bolt of the underbody cover of model B is 16mm. When switching models, the fasteners need to be switched at the same time, and the risk of wrong installation is high. Change the length of the fastener of the bottom guard of model B to 20mm, which is the same as that of model a, so as to avoid the wrong installation of the fastener for model switching.

(3) Structural error proofing

Structural error proofing refers to the unique assembly of parts in structural design, which can be realized by positioning, structural matching and so on. If the five limit posts of the front logo are consistent with the openings of the grille trim, they can be assembled correctly, otherwise the front logo cannot be assembled with the grille trim.

Figure 5 error proofing of logo structure

(4) Identification error proofing

For similar parts that need to be visually distinguished to prevent errors, marks shall be engraved or pasted on the surface that does not affect the appearance and commodity. Like the “L” and “R” of the left and right parts in the model, or the combination of model name and part number. The visual effect is better when similar parts between different models are distinguished with label paper of different colors. Because distinguishing colors is more accurate and efficient than distinguishing words. For some non appearance commercial parts, the color of the part body can be distinguished. If the color of the temperature sensor of model a is white, the outer surface color of the part of model B can be defined as black.

Figure 6 identification error proofing

Part 2. Error proofing strategy in manufacturing stage

The whole vehicle product is assembled on the final assembly production line. The final assembly production line is the most important and final link in the implementation of the final assembly error prevention system. The ideal state of error prevention is error prevention without manufacturing defects, which is an active, economic, predictable and error prevention control technology. Of course, in order to ensure zero outflow of defects, necessary inspection will be added in the whole vehicle production process, and this inspection is also a means of error prevention, but this inspection theoretically does not produce practical value, and the ideal state is error prevention in the process.

(1) Scan error proofing

According to the requirements of the quality assurance system, the key parts of the whole vehicle shall be subject to traceability management, so as to quickly determine the object range in case of problems and minimize the trouble brought to the next process. When a crisis occurs, it can accurately determine the scope of the object and minimize the loss. For the parts traced by scanning the bar code, the bar code has the specification verification number and part brief number for error prevention. When scanning the bar code, the computer automatically identifies whether it is wrongly installed, and interlocks with the production line. When there is a mismatch, the production line will automatically stop, so as to prevent the wrong installation.

(2) Error proofing of tooling and equipment

Error proofing by adding tooling, equipment and devices. For example, for the sub assembly tooling or fixture of some parts, sometimes in order to save costs, the parts with small differences are designed as general tooling, which has no error proofing effect. For the parts assembled by tooling or fixture, an error proofing mechanism can be set on the tooling to make the tooling or fixture not universal, so as to play the role of error proofing. The error proofing device is added to the equipment to enable the equipment to have the ability of automatic error correction, carry out real-time detection and judgment on the correctness of the operation, stop immediately if an error is found, and automatically give an alarm to inform the operator of the error, and do not continue until the operator corrects the wrong assembly. The application of error proofing device technology on equipment is generally error proofing without manufacturing defects, eliminating rework and reducing inspection cost, which is a more economical error proofing measure.

Figure 7 simple tooling

(3) Error proofing of distribution method

SPS is a method of supplying parts to operators. One of the advantages of SPS is that the sorter focuses more on whether the specifications of parts are correct and sorts the correct and qualified parts for the trolley. The operator is more focused on the operation to ensure the assembly quality. SPS rack equipped with lighting system will light up green at the outlet of the corresponding rack after scanning the vehicle information. It will turn red only after the sorter takes the part, which can effectively prevent wrong loading and missing loading.

Figure 8 SPS logistics distribution diagram

(4) Specification differentiation error proofing

There are many parts. Considering the cost and error proofing level, not all parts can be error proofed by scanning and tooling and equipment. For these parts, we must rely on the role of rigorous quality assurance system to prevent errors. The error proofing of such parts depends on the appearance that can be easily distinguished. As mentioned above, they are marked, color marked, color distinguished, etc. in the design stage. If this kind of parts are not considered in the design stage, the error prevention ability in the manufacturing stage will be very weak. Because in the production line with high chain speed, it is difficult to distinguish the parts without obvious difference with the naked eye, and it is easy to make mistakes. Obvious appearance distinction is the basis. To prevent wrong assembly, the operator also needs to know the difference of each part and the model of each part to be assembled, which requires the operator to have relevant operation documents. The identifiable differences between parts and corresponding assembly models shall be specified in the operation documents, and the operators shall be trained before taking the post to make them familiar and convenient for inquiry when necessary. And through training and process discipline supervision and other means to improve their operation execution, so as to ensure that employees confirm the parts according to the operation requirements during assembly. It is necessary for operators to improve their ability to prevent mistakes in the process by arranging visual inspection or mutual inspection.

As shown in Figure 9, in order to improve the misuse of parts produced in the same line and improve the part placement box, only the parts of the required model can be taken out. When the limit switch is installed on the production line, it can automatically check the model of the current assembly. The currently unused parts are covered by a device pushed by the limit switch to eliminate the problem of mixed use of parts.

Figure 9 error proofing of parts box for CO production

(5) Process error proofing

For example, a certain anti-theft horn is often missing, which is not easy to find after missing, resulting in problem outflow. The improvement measures are as follows: the installation steps of anti-theft horn are decomposed, and the plug-in insertion, installation and fastening are carried out in different stations. After the missing installation in the previous process, the next process cannot be operated, which fundamentally solves the problem of missing installation.