​Case Study: Streamlining Joint Robot Procurement for Brazilian Automotive Parts (76 Units)​​

​1. Client Requirements​

· ​Functional Needs:

o ​Material Handling: Transport heavy engine components (up to 100 kg) and small brake parts across assembly lines.

o ​Welding: Precision arc welding for chassis joints and spot welding for electrical components.

o ​Painting: Uniform coating application on aluminum alloy brake calipers and body panels.

· ​Technical Demands:

o ​Accuracy: Welding tolerance ±0.1 mm, painting thickness consistency ±0.2 mm.

o ​Durability: 24/7 operation in high-temperature (40°C) and dusty environments.

​2. Challenges

· ​Supplier Screening:

o Identified 32 qualified suppliers from hundreds of China joint robot manufacturers to conduct a initial evaluation of production capacity, scalability, and compliance with automotive-grade standards.

o Selected 6 manufacturers providing automation solutions for customer’s final decision.

· ​Factory Audits:

o Conducted ​on-site audits​ at shortlisted facilities (e.g., EFORT, JAKA,ESTUN,etc.) to verify:

o Produced ​detailed audit reports​ highlighting difference of 6 suppliers’ workflow efficiency.

· ​Technical Collaboration:

o Co-developed ​customized welding paths​ for chassis components using client’s CAD drawings.

o Resolved ​compatibility issues​ between robot controllers and client’s legacy AGV systems.

3.Our Solutions

· ​Supplier Contract:

o Conducted ​factory audits​ at facilities to verify production capacity, quality control systems, and compliance with automotive-grade standards.

o Reviewed Joint Robot certifications.

· ​Production Oversight:

o Installed IoT sensors on assembly lines to monitor welding torque calibration and paint nozzle pressure in real time.

o Performed ​6 mid-production inspections​ to align assembly accuracy with client specifications.

· ​Acceptance Support:

o Coordinated ​3-day validation tests​ at the client’s Brazilian facility, including:

§ Weld strength testing (tensile force ≥ 350Mpa).

§ Paint adhesion checks using cross-cut tape tests.

o Trained 20 technicians on robotic programming and emergency shutdown protocols.

​3. Outcomes​

· ​Operational Efficiency:

o Welding throughput increased by 35% (10.5 → 14.2 units/hour), reducing bottlenecks in chassis production.

o Painting cycle time shortened by 28% via optimized spray patterns and reduced rework.

· ​Quality Assurance:

o Weld defect rate dropped from 6.1% to 1.5%, meeting OEM durability standards.

o Paint uniformity improved by 19%, eliminating rework costs.

· ​Cost Savings:

o Energy consumption reduced by 25% through optimized motion paths.

o Maintenance costs cut by 40% with predictive wear monitoring systems.

​Post-Project: Client achieved full automation in critical workflows, enabling a 20% expansion of production capacity and price advantages in Brazil’s automobile market.