1. Case Basics 
Ningbo zhongjun senchi | automobile interior and exterior parts injection molding + painting digital workshop (MES + WMS + IOT + lamp installation) landing case 

Customer name : zhongjun Senchi Auto Parts Co., Ltd. (Ningbo Factory)

Industry : auto parts (interior and exterior trim, injection molding/painting/assembly)

Enterprise scale : large listed enterprises, primary suppliers of global mainstream car companies 

Project cycle : March 2024-August 2024 (total cycle 6 months)

2.The customer's original pain points 
Combined with the actual project, the specific pain points are described as follows:

Production pain point : planned manual release, randomness; Progress and work-in-progress cannot be monitored in real time; Production scheduling is opaque and delivery guarantee capacity is insufficient.

Logistics/storage pain points : material accounts do not match, line and side warehouses are chaotic; Turnover box/high-value packaging materials have no digital management; First in, first out is difficult to execute and material finding takes time.

Quality/traceability pain point : inspection relies on manual work and has a high rate of missed inspection; There is no whole process batch traceability; If there is a quality problem, it is impossible to quickly locate raw materials/equipment/processes/personnel.

Management/system pain points : equipment is not networked, status and parameters cannot be collected; Manual statistics of data lag; Multi-workshop data island, management cannot make real-time decisions.

Equipment/mold pain points : equipment inspection and maintenance are not standardized; The mold has no ledger and no product binding. There is no mistake in changing the mold and the wrong mold is easy to use. 

3. Our solution : With "intelligence, collaboration and transparency" as the core, the customized solution is as follows:

Deploy the system :MES Manufacturing Execution System + WMS Warehouse Management System + IOT Equipment Networking Collection + Andon Lighting System + Supplier Portal + BI Data Analysis Platform 

Hardware Configuration :PDA mobile terminal, industrial computer, MINI screen, wall-hanging kanban, equipment data acquisition terminal, visual recognition terminal 

Implementation content : cover the four major processes of injection molding, painting, puncture welding and assembly workshop; phases will not stop production and go online: injection MES in March → coating MES + WMS in April → assembly MES in May → overall acceptance in August; On-site training + practical operation guidance + multiple rounds of key user empowerment; Customized development of industry differentiation functions such as label error prevention, batch traceability, mold binding, skid management 

System integration : deeply connect with customer SAP ERP, open up PLM, OA and equipment PLC, realize data exchange and business closed loop 

4. project implementation effectiveness 
After the digital transformation, the core indicators have improved significantly:

Efficiency class : execution efficiency is improved by 30%, picking efficiency is improved by 30%, production cycle is shortened by 30%, and data collection efficiency is improved by 90%.

Quality class : human error reduced by 99%, information error reduced by 90%, inspection efficiency improved by 30%, and full traceability coverage rate by 100.

Cost category : indirect labor costs are reduced, inventory and sluggish materials are reduced, material loss is reduced, and manufacturing costs are significantly optimized.

Management class : the delivery punctuality rate has been significantly improved; The operating rate of equipment can be quantified and improved. Production is fully transparent and visualized. Abnormal automatic lamp warning improves processing efficiency. 

5. Case Highlights the following are the core values and innovations of this project:

Integrated digitization of the whole workshop : injection molding/coating/assembly/storage is fully covered, and the "one game" management of auto parts factories is truly realized.

Industry-level error prevention and traceability : label error prevention, feeding error prevention, mold scanning code verification, batch full-link traceability, meeting the compliance requirements of first-level suppliers of automobile enterprises.

Equipment networking + data driving :34 injection molding machines +3 coating lines +30 puncture welding equipment are fully networked, and OEE, process parameters and energy consumption are visible in real time.

Lightweight and Fast Landing : Complete the full function online in 4 months, do not stop production and reform, employees get started quickly, and customers issue formal commendation letters.

Customized scene landing : mold product binding, MINI screen one-button mold change, skid utilization statistics, high-value turnover box management, suitable for auto parts business.