Printing Solution for an Automotive Assembly Line - Industry Cases

Client Profile

An automotive manufacturer responsible for stamping, welding, painting, and final assembly in its vehicle production process is committed to delivering higher-quality automotive products and services to consumers. The company embraces digital management, continuously optimizes production processes, enhances product quality and service levels, and prioritizes environmental protection and sustainability.

Business Challenges

Multiple Printing Tasks at the Same Production Line Point: Different printing media, sizes, and weights need to be handled at the same production point, such as printing the three certificates in one (qualification certificate, consistency proof, and fuel label). The previous supplier deployed multiple printers at the same location, leading to high printing equipment costs for the production line.

Harsh Automotive Production Environment: The production environment is harsh, with fluctuating temperatures and humidity levels, requiring highly durable equipment. The previous equipment frequently failed, impacting production efficiency.

Lack of Control Software: Without a control software solution, equipment failures or toner depletion were not promptly detected, resulting in extended downtime.

Nationwide Factory Locations: Factories are spread across various regions, including some in smaller cities. The previous service provider was slow to respond, making it difficult to find maintenance personnel when needed.

Solution

Durable Printing Equipment for Manufacturing Lines: Provided robust printing equipment capable of handling the centralized output of the three certificates in one on various media. The printer can be equipped with binders and separators, with a maximum monthly printing capacity of 300,000 pages, suitable for any production line.

Implementation of Digital Monitoring Software: Launched digital monitoring software to continuously monitor equipment status, enabling preventive inspections and reducing fault response times.

24-Hour On-Site Service: Offered around-the-clock on-site service, strictly adhering to a regular maintenance schedule that includes cleaning, calibration, and the replacement of worn parts to keep equipment in optimal condition.

Ample Spare Parts Inventory: Maintained a sufficient inventory of spare parts to ensure immediate replacements when necessary, minimizing downtime. Each failure is analyzed in detail to identify the root cause and prevent recurrence.

Nationwide Service Network: Established a nationwide service network to meet the on-site repair needs of factories located in smaller cities.

Solution Advantages

Tailored Equipment Selection: Selected suitable printing equipment and established uniform standards based on the different operation types and media at various points on the production line.
Seamless Integration: Integrated the printing solution with the client's internal production system, optimizing and upgrading the vehicle documentation printing process.
Proactive Digital Management: Utilized tools to monitor equipment status and provide real-time alerts for consumable shortages. Automatically pushed notifications for equipment issues.
On-Site Engineering Support: Provided professional on-site engineers to respond promptly to issues. Implemented 5S management standards for consumables, inventory, and personnel.
Comprehensive Service Network: Established a service network across major cities to ensure a 4-hour on-site response, and next-business-day on-site capability in over 200 cities.

Results & Values

Zero Complaints During Service Period

Managed printing maintenance services for multiple production lines. By leveraging the cloud management platform and 24-hour on-site service, established a rapid response mechanism to efficiently resolve production line printing issues. Continuously innovated service models and content based on client needs, providing a more comprehensive and convenient service experience, resulting in zero complaints during the service period.

Zero Production Line Downtime During Service Period

Provided 24/7 on-site and remote services, with a 5-minute response time for critical workstations and a 2-hour fault repair time. If the issue couldn’t be resolved within 2 hours, a backup machine was provided immediately. Ensured 24/7 normal operation of printing equipment, achieving an SLA completion rate of 99.99%.

Cost Reduction and Efficiency Improvement

Optimized the deployment of printing equipment and digital management tools, reducing the client's production line printing costs by 30%.