In today's highly competitive manufacturing environment, enterprises are confronted with multiple challenges: increasingly personalized customer demands, accelerating product updates and iterations, and continuously rising cost pressures. Against this backdrop, the "stamping + machining" integrated production model first proposed by Dongguan Zhongchuangxing Precision Machinery Manufacturing Co., Ltd. is becoming a new trend in the precision manufacturing industry.
The pain points of the traditional decentralized manufacturing model
The traditional manufacturing of precision components often adopts a decentralized processing approach: stamping parts are completed in one factory, machining is carried out in another, and surface treatment may take place in a third factory. The drawbacks of this model are obvious:
High communication costs: There are differences in technical standards and process understanding among different factories, which requires a great deal of communication and coordination.
The delivery date is hard to guarantee: logistics transportation, queuing and waiting, and process connection can all cause time delays.
Quality control is difficult: Quality problems may occur at every stage, and responsibility is hard to trace.
The overall cost has risen instead of falling: It seems that the "lowest-priced" supplier has been found in every link, but the hidden costs are often overlooked.
The core value of integrated manufacturing
The integrated model of Dongguan Zhongchuangxing has fundamentally solved these problems:
1. Seamless production process
Our factory has achieved physical connection and information system integration between the stamping workshop and the machining workshop internally. From stamping to machining, the product goes through different processes on an assembly line, without the need for outsourcing or waiting. This not only shortens the production cycle, but more importantly, reduces the risk of product damage and quality changes during transportation.
2. A fully traceable quality system throughout the process
We have established a full-process quality traceability system from the entry of raw materials into the warehouse to the exit of finished products. Each part can be traced back to: when, what material, which equipment and which operator produced it. This transparent management ensures the consistency of quality and also facilitates the rapid location and resolution of problems.
3. The possibility of collaborative optimization of processes
When stamping engineers and machining engineers work in the same team, they can collaborate from the early stage of product design. For instance, when designing stamping dies, the clamping positions for subsequent machining are taken into consideration. When formulating the machining plan, the characteristics of stamping forming can be fully utilized to reduce the machining allowance.
Actual case: Manufacturing of automotive sensor housings
Take the aluminum housing of a certain automotive sensor as an example:
Traditional mode: Stamping forming (7 days) → transportation to the machine processing factory (2 days) → queuing and waiting (3 days) → CNC processing (5 days) → total time consumption: 17 days
Zhongchuangxing integrated model: Stamping forming (3 days) → internal circulation (0.5 days) → CNC processing (4 days) → Total time consumption 7.5 days
The delivery time has been shortened by 56%, and due to the reduction in clamping times and circulation links, the key indicators such as coaxiality and flatness of the products have improved by 30%.
Support for technical implementation
Integrated manufacturing is not merely a simple accumulation of equipment, but rather requires strong technical support
Intelligent production management system: Our independently developed MES system has achieved intelligent scheduling of production plans, ensuring a balanced match of stamping and machining capacity.
Standardized process database: It has accumulated the composite process parameters of stamping and machining for thousands of materials, providing data support for the development of new projects.
Interdisciplinary talent team: A group of compound engineers who are proficient in both stamping and machining have been cultivated. They are the key to achieving process collaboration.
Industry impact and Future outlook
With the in-depth development of Industry 4.0, the trend of integration and intelligence in manufacturing is irreversible. The integrated model of Dongguan Zhongchuangxing not only creates tangible value for its clients but also provides a reference model for the entire industry.
In the future, we will further deepen this model:
Expand to the integration of more processes, such as surface treatment, heat treatment, etc.
Introduce artificial intelligence technology to optimize process parameters.
Establish a process prediction model based on big data.
