To accommodate the production requirements of diverse wire harness, a domestic automotive wire harness connector manufacturer has successfully implemented a multi-functional production model by adopting MIJOINT's automated production line solution for automotive Fakra wire harness assembly. The following is a detailed analysis of this case.
Processes
The key processes of this equipment include wire stripping, detection of filaments of braided sleeve, pressure monitoring, and assembly depth control.
Challenges
On one hand, the customer's single-function production lines struggled to meet the production needs of various products. On the other hand, the equipment's overdependence on operator skill levels also compromised quality consistency. Moreover, the customer hoped to reduce product costs to capture market share in the new energy automobile wire harness sector.
Evaluation
The production line with single functionality struggled to adapt to various product requirements and handle diverse orders, which led to losses. Besides, its failure to meet end-customers' demand for stable quality of products made by fully automated equipment also undermined the company's competitiveness. Management and labor costs were under significant pressure.
Solutions
Based on the customer’s existing production line and product quality specifications, we developed an automotive Fakra wire harness assembly auto line to meet their demands for flexibly switching production mode and reducing labor and management pressure. Our implementation steps are as follows:
1. Upon receiving the requirements, we communicated with the customer to assess risk points. We developed a fully automated production & inspection line integrated with an MES system and utilizing AIDI deep learning technology for 360° no-dead-angle detection of filaments of braided sleeves.
2. It integrates crimping pressure monitoring and displacement sensor-based assembly compensation (achieving assembly accuracy of 0.03mm) to achieve 100% full inspection and full-process data upload for traceability.
3. The production line employs modular program design, allowing flexible compatibility with operation modes like manual or automatic loading.
4. Operators can switch production programs with one click based on order requirements to rapidly match different production modes without line stoppage and reconfiguration.
Results
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Performance Indicator
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Before Improvement
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After Improvement
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Improvement Range/Effect
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Hourly Capacity (Per Capita)
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100 pcs/15 HC
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500 pcs/1HC
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Hourly capacity increased by 5 times, per capita efficiency significantly improved
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Labor Configuration per Shift
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15 HC/shift
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1 HC/shift
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14 HC saved per shift, labor cost reduced by 93%
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Production Mode Changeover Time
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Line stoppage and reconfiguration required (several hours)
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One-click switching (approaching 0)
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Changeover efficiency greatly improved with no production interruption loss
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Product Yield
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Unstable (affected by filaments of braided sleeve)
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Stabilized above 99.5%
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Yield stability significantly improved, defective product cost reduced
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