The Challenge
GREE faced significant bottlenecks in their air conditioner back panel assembly, specifically regarding the high-precision alignment of complex multi-component structures. Traditional riveting methods resulted in low throughput and inconsistent quality. The objective was to implement a smart, mixed-model production line capable of handling diverse product variants with minimal downtime.
SIMITCH Solutions
SIMITCH engineered a turnkey, fully automated production line featuring:
Intelligent Assembly
Integrated robotic loading with advanced machine vision for micrometer-level alignment of diverse sheet metal components.
High-Throughput Riveting
A multi-unit synchronous riveting system that saves takt time by 300%.
Agile Changeover
Modular tooling and programmable logic enable rapid model transitions in under 5 minutes, maximizing production uptime.
Data-Driven Quality Control
Real-time monitoring and synchronization with the Manufacturing Execution System (MES), ensuring 100% digital traceability for every joint.
Results
- Labor Efficiency: Achieved a 60% reduction in headcount by replacing manual stations with full automation.
- Production Capacity: Increased overall production efficiency by approximately 2.5 times.
- Quality Consistency: Drastically improved riveting precision, leading to a significant reduction in product defect rates.
- Strategic Value: Provided essential hardware and data infrastructure for GREE’s “Smart Factory” demonstration project.
“This automated riveting line is exceptionally stable and reliable. It has effectively addressed the long-standing efficiency and quality pain points in our back panel production, making it a critical asset in GREE’s intelligent manufacturing ecosystem.”