April 21, 2025
Integrated production control refers to the process in which enterprises independently control the entire process from product design to finished product delivery through their own factories, thereby improving efficiency, quality, and cost advantages.
1. Industrial design stage
Design and Manufacturing Collaboration: Early involvement of design teams and factory engineers to avoid design drafts being unable to be produced (such as overly complex structures, mismatched materials, etc.).
DFM (Design for Manufacturing): Consider the difficulty of mold development, casting process limitations (such as wall thickness and draft angle), and feasibility of later polishing during the design phase to reduce rework.
Rapid prototyping verification: Verify the rationality of the design through 3D printing or CNC machining for rapid prototyping.
2. Mold development stage
High precision mold manufacturing: Our own mold workshop can strictly control tolerances (such as ± 0.01mm) to ensure consistency with design drawings and avoid communication errors in outsourced processing.
Trial mold and adjustment: Conduct a trial mold before casting to check for defects such as shrinkage holes and flow marks in the blank, and optimize the mold pouring system and cooling system.
Life management: Extend mold life and reduce mass production costs through material selection (such as SKD61 steel) and surface treatment (such as nitriding).
3. Product casting stage
Process selection: Choose die casting, gravity casting, or precision casting (such as silica sol casting) according to product requirements to control costs and precision.
Parameter standardization: Parameters such as melting temperature and injection speed are monitored by the system to ensure batch stability.
Real time defect detection: By using X-rays or ultrasonic waves to detect internal porosity, inclusions, and other issues in castings, the process can be adjusted in a timely manner.
4. Polishing and surface treatment
Automated polishing: Robot polishing is used for complex surfaces to ensure consistency; Hand polishing is designed for high gloss surfaces or special edges.
Multi level polishing process: rough polishing (such as 400 # grinding wheel) → fine polishing (such as 800 # wool wheel) → mirror treatment (such as chemical polishing), to meet different surface requirements.
Cleaning control: Avoid residual polishing dust, which may affect the adhesion of subsequent electroplating or spraying.
5. Quality inspection closed-loop
Combination of full inspection and sampling inspection: 100% full inspection of key dimensions (such as assembly interfaces), and appearance sampling inspection shall be carried out in accordance with AQL standards.
Detection method:
Coordinate Measuring Machine (CMM) is used to measure three-dimensional dimensions;
Spectrometer analysis of material composition;
Salt spray test to test corrosion resistance.
Data traceability: Each product is bound with a unique number to record data from various stages (such as casting parameters and quality inspectors) for easy problem traceability.
