At Ocean Century (Qingdao) Industrial Co., Ltd., we turn manufacturing challenges into competitive advantages. This case study details how our sheet metal division's strategic automation of “angle steel” welding resulted in a 112.5% efficiency gain and a dramatic 90% reduction in defect rates.
The Challenge: Inefficiency and Inconsistency in Manual Welding
Our sheet metal fabrication process for a critical component—the left and right angle steel—was constrained by reliance on manual welding. This traditional method presented two core bottlenecks that impacted quality and delivery:
Unstable Quality: Weld quality was entirely dependent on the individual operator's skill and focus, leading to inconsistent weld beads and a persistently high defect rate of 10%.
Production Bottleneck: The single-operator, single-station model was inherently slow, capping daily output at just 1,600 pieces per person. This severely limited our capacity to meet growing demand and rapid-delivery requirements.
Our Engineering Solution: Precision Laser Welding Automation
To address these challenges head-on, a dedicated improvement team at Ocean Century, led by Production Director Chen, engineered a comprehensive automation solution centered on advanced laser technology.
Process Optimization: We replaced the manual spot welding with an automated, continuous laser welding system. By optimizing key parameters, we achieved a uniform, high-speed, and exceptionally stable weld.
Workflow Integration: We introduced custom-designed fixtures and a dual-station alternating program. This innovation eliminated the need for manual flipping and re-welding, creating a seamless, continuous production flow and maximizing equipment utilization.
The Measurable Results: Quality and Efficiency Transformed
Quality Leap: The welding defect rate plummeted from 10% to just 1%, achieving a consistent product qualification rate of over 99%.
Breakthrough Efficiency: Per-person daily output skyrocketed from 1,600 to 3,400 pieces, marking a 112.5% efficiency increase. Furthermore, the automated process reduced labor requirements by 2 operators per machine, optimizing human resource allocation.
A Scalable Model for Future Automation
The success of this angle iron welding project extends beyond a single production line. It serves as a replicable "automation template" for Ocean Century. The same technical principles and implementation model have already been successfully applied to other welding lines, such as base steel plate angle irons, proving its value as a scalable solution for various metal fabrication scenarios.
This strategic upgrade is a testament to our commitment to "Intelligent Manufacturing" and our core philosophy of continuous improvement. It showcases our ability to leverage technology to solve complex production problems, delivering superior value to our clients through higher quality and greater efficiency.
Is your manufacturing process hindered by similar bottlenecks in welding or assembly?
Let Ocean Century's expertise in precision sheet metal fabrication and process automation help you achieve a transformative breakthrough.
[Contact Ocean Century Today to Optimize Your Production Line]
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