For the construction of a high-end automated production line for high-precision valve parts weighing more than thousands of kilograms and with a batch of at least 10 pieces, Mr. Liang Guihua, chairman of Xipai Group Co., LTD., made this decision in 2019, almost all the company’s senior executives were opposed and questioned by peers: “Such a small batch of automation is not sensationalistic”, “all kinds of different types of valves, different sizes and all kinds of special materials, how to achieve automation”, “how to ensure product quality”… Now, in the past three years, this integrated 6 high-end processing centers, the length of nearly 100 meters, can be called the Asia-Pacific region’s largest flexible production line for multi-variety small-batch production has been successfully run, in the production efficiency doubled, production personnel reduced by 40% excellent performance to smash all doubts at the same time, but also become the “fixed sea needle” of the west intelligent Dream Factory. It has laid a solid foundation for its ranking among the most complete high-end valve manufacturing enterprises in China.

“For manufacturing companies, to be better, they must have their own unique advantages. For the West, I think it’s intelligence.” Mr. Liang Guihua introduced, “Anchoring the lights-out factory and the digital factory, Xipai is taking this flexible line as the starting point to continue to strengthen the core barriers for future manufacturing challenges.”

The largest hybrid flexible production line in Asia Pacific for multi-variety and small-batch production

Founded in 2009, Xipai is a high-end intelligent enterprise focusing on fluid control solutions. It has been engaged in the research and development and production of special equipment for oil drilling and production, pipeline valves, control valves, instruments and instruments. With high performance and high precision products, it has become a national Petroleum Company, Sinopec Company, and Sinopec Company. And Kuwait National Oil Company (KOC), ABU Dhabi National Oil Company (ADNOC), Algeria’s SONATRACH and other leading energy enterprises tier 1 suppliers, has a high reputation and influence in the industry.

Entering the factory located in Jinhu, Jiangsu Province, whether it is a modern factory with cutting-edge design, intelligent and efficient production equipment, automated production line, or a very futuristic data monitoring hall, its advanced level is amazing. As a provincial leader said during the visit, “I did not expect Jinhu to have such advanced enterprises, and I did not expect Jinhu to have such entrepreneurs with advanced ideas.” Behind all this, it is impossible to avoid the profound and forward-looking thinking of its leader Mr. Liang Guihua.

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Competition will only be more intense, on the one hand is the two-way attack of domestic giants and overseas brands, on the other hand is the rapidly changing needs of users, only by taking the intelligent route can the West have a ‘differentiated competitive advantage’.” We started planning a few years ago until we met Fastems in 2019.” Mr. Liang Guihua introduced, “Through the many successful cases of Fastems all over the world, I have seen what the flexible production line in my vision looks like; In many in-depth discussions, I really feel the Fastems’ different ‘, they always stand in my point of view, won my trust.”
It is worth mentioning that Xipai flexible production line not only set a record in length, but also the mixed and complex level of its production line is second to none in the industry. The first is the mix of different brands of machine tools, western production line integrated Okuma and Makino two brands, different specifications of six four-axis four-linkage machining center, which not only requires the production line integrator has a strong brand compatibility, but also needs to have rich application experience. One difficulty is also a highlight: the mix of pallets of different sizes and functions. In order to match the two types of machine tools, 159 machine pallets in the production line have two different sizes, respectively 630*630mm table horizontal and 800*800mm table horizontal, in addition to 118 1200*800mm material wooden pallets, flexible line needs to intelligently identify each pallet, And accurately send them to the corresponding material station or machine tool, for the performance of flexible control software is also a small test.
Mr. Ding Yongping, general manager of Fenfa Automation Shanghai Co., LTD., said: “Different brands of machine tools, different pallet sizes and material pallet management, has never been a company’s ‘patent’, and Fastems can undertake this project, and ensure the smooth operation of the production line of certainty and confidence, are from our more than 40 years of experience in the field of automation. Which brand of machine tool is equipped with what interface, how the palletizer can switch to recognize different sizes of pallets, how the flexible control software can meet the different needs of users, these questions have been successfully verified countless times in our thousands of cases around the world. In addition, the installation and commissioning of the Xiapai flexible line were completed by our China service team, which was highly recognized by the customer, which is also a strong proof that Fastems China positioning is’ global technical standards, local response speed ‘.”

“The longest flexible production line, with the fewest people”

When entering the workshop, this flexible line really stands in front of the eyes, the shock it brings is beyond description. It is seen that the length of nearly 100 meters and the height of nearly eight meters are neatly arranged, and there is an integrated palletizing machine in the library, which efficiently and orderly carries all kinds of pallets and the blanks on the pallets and the products in process to six machine tools and three loading stations in the production line at a super-fast speed of 210 meters per minute. All processes are performed by only two technicians, operating the control panel and clamping parts.