RMU production is not the addition of single machines but the coordination of multiple processes. Gas tank assembly, secondary assembly, welded structures and inspection stations are closely related. An unstable front-end cycle blocks the inspection area, welding quality variation causes repeated rework, and unclear material flow makes the workshop depend on manual memory. Taizhou Yufeng Intelligent Equipment Co., Ltd. designed an overall solution of a secondary assembly line, wiring line and robotic welding cell for an RMU manufacturer.
Project pain points
The customer's RMU production had three types of problems. First, secondary assembly and wiring depended on manual experience with inconsistent operation order. Second, some welded structural parts had quality variation that affected downstream assembly. Third, material and work-in-process flow lacked standards, and the site was easy to become disordered. The customer wanted a stable flow from structural parts to secondary assembly.
Solution design
We planned a secondary assembly line and wiring line, dividing secondary assembly into component installation, cable harness prefabrication, termination and inspection stations with standardized operation order. A robotic welding cell handled structural welding with automatically controlled parameters to reduce quality variation. The line was connected by a conveying system, work-in-process flowed at a fixed cycle, and buffer positions balanced differences between stations.
Implementation and results
After implementation, secondary assembly operations were unified and standardized, wiring quality was consistent, and welded structural parts were stable. Material flow was clear and work-in-process inventory decreased. The customer reported a more stable line cycle, lower rework rate and no more blocking in the inspection area. The unified production flow also made training and daily management simpler.
Project insight
For multi-process products such as RMUs, the key to improvement is opening up the logistics and cycle between processes rather than optimizing a single machine alone. When assembly, wiring and welding are organized into a continuous flow, overall efficiency and quality improve together.
For an RMU secondary assembly line, wiring line or robotic welding cell solution, contact Taizhou Yufeng Intelligent Equipment Co., Ltd.