Full-line delivery for a galvanized hardware mounting production line

Case Study 01 · Four months: A production line from site survey to stable mass production

[Customer Name]The client's existing electroplating line had been in operation for several years but suffered from low automation levels and significant fluctuations in coating uniformity. As order volumes increased, both production capacity and quality faced critical challenges, while the company also encountered increasingly stringent environmental compliance requirements. After comparing multiple solutions, the client ultimately chose to engage us for the full-scale delivery and installation of the entire production line.

The client's existing production line is facing three major obstacles:

• Production capacity bottleneck: Dependence on manual loading/unloading and operational processes results in a daily production capacity of approximately 3,000 units, which is insufficient to meet the growing order volume.
• Quality variation: Poor coating thickness consistency; first-pass yield approximately 92%; high re-coating rate.
• Environmental compliance challenges: Inadequate exhaust gas collection and wastewater treatment systems expose the facility to risks of regulatory rectification and compliance inspection.

The entire process-from the initial site survey to stable mass production-takes approximately 16 weeks; the following steps and timelines are illustrative data intended to help understand the delivery schedule.

(1) Preliminary Surveying and Customized Planning and Design

Week 1–3: Survey & Custom Design

The engineer conducted two on-site survey visits, translating the client's requirements – "demand for production capacity, quality, and compliance" – into a practical production line solution, and finalized the proposal within two weeks.

• Surveying the factory building (1200 m², ceiling height: 6 m; structural load-bearing and power distribution systems – confirms the need for an additional capacity of 200 kVA).
• Select an alkaline non-cyanide galvanizing process and design the hanging fixtures and bath arrangement according to the workpiece dimensions.
• 28 workstations with slot-based layout; cycle time: 300s per unit; reserved for future capacity expansion workstations.
• Generate 3D layout diagrams, equipment lists, and investment budgets – achieve client approval on the first attempt.

Key performance indicators: 28 workstations with slot-based layout; 300 s/h design cycle time; 5,200 units/day design capacity

Delivery: Customized design solutions, equipment list, and quotation

(2) Precision Equipment Manufacturing and Factory Commissioning

Week 4–10: Fabrication & Pre-commissioning

All core equipment is manufactured at our own factory and undergoes a 72-hour no-load integration test as well as 42 item-by-item inspections prior to shipment; upon delivery, the equipment can be installed immediately.

• 18 stainless steel/PP troughs manufactured, including anti-corrosion lining, heating and circulating filtration systems
• PLC automatic control system + Touchscreen HMI; integrated rectifier power supply and temperature control instrument
• Longmen crane, transmission mechanism, mounting fixtures and anode fabrication – dimensional verification for each component
• The equipment underwent a 72-hour integrated trial run at the factory; all 42 factory acceptance tests were successfully passed; the shipment was dispatched 5 days in advance.

Key indicators: 18 customized tank units; 42 factory acceptance tests; 72-hour integrated trial operation

Delivery: Factory Commissioning Report, Equipment Inspection List

(3) Selection and Compatibility of Specialized Pharmaceutical Reagents

Week 10–12: Pharmaceutical Formulation – Chemistry & Formulation

The laboratory first performs sample preparation to establish a consistent process by optimizing the plating solution formulation and equipment parameters; the test samples are then subjected to salt spray and thickness testing as approved by the client before undergoing final curing.

• Alkaline non-cyanide galvanizing system selection: matching the primary salt, complexing agent, brightener and passivating agent
• Laboratory: Conduct 20 batch-specific formulation pilot tests; compare samples from the same production batch and select the optimal option.
• Check coating thickness uniformity (CV <5%); neutral salt spray test (96 h) – no white rust (example).
• Process parameters are permanently programmed into the PLC;Bath Maintenance and operating manuals are delivered simultaneously.

Key performance indicators: 20 formulation pilot tests; 96-hour neutral salt spray test; <5% thickness CV

Delivery: Process Parameter Manual, Chemicals Supply List

(4) On-site installation and comprehensive commissioning

Week 13–16: Installation & Commissioning

The engineer was stationed on-site for 22 days to complete the installation; followed by a 7-day load-tested production run to verify compliance with all requirements; the sample parts passed a single third-party random inspection; and all operational capabilities were fully handed over to the client team.

• Civil engineering foundation verification, embedded components, and simultaneous connection of exhaust and wastewater pipelines
• Complete equipment installation, tank pipeline and circuitry installation, and crane track installation within 22 days.
• Single-machine → Full-line integration → No-load operation → Step-by-step load testing; 7-day load trial production
• Three sessions of operational, maintenance and safety training; third-party sampling and acceptance inspection for trial production samples

Key metrics: 22-day on-site installation; 7-day loaded trial production; 99.2% first-time yield rate for trial production

Delivery: Acceptance Inspection Report, Training and Operational Records

(5) Post-implementation Operation and Maintenance & Lifetime Technical Support

Continuous O&M Support · O&M & Lifetime Support

Post-commissioning support is not yet complete: regular follow-up visits, spare parts availability, and remote diagnostics are continuously monitored, and proactive upgrade solutions are offered as the customer's business grows.

• Four scheduled follow-up visits in the first year; records of tank solution composition and equipment condition inspections shall be archived.
• Spare parts inventory – commonly used wear parts delivered within 48 hours
• Three remote diagnostic sessions + two on-site response visits – all resolved within the committed timeframe.
• The following year, in response to growing order volumes, a plan for automation upgrades and capacity expansion was proposed.

Key metrics: 4 scheduled follow-up visits per year; 48-hour spare parts response time; dual-channel remote + on-site support

Delivery: O&M Service Documentation, Lifetime Response Guarantee

The following images are for illustrative purposes only; they may be replaced with actual photos from your company's project.

• The entire production line is delivered in its entirety after completion of manufacturing and preliminary commissioning at the client's own factory (illustrative material).
• Galvanized workpiece: uniform and dense coating with a silvery-white surface finish (illustrative sample)
• Full-line integrated commissioning: Joint commissioning of the electrical control system and process parameters (illustrative material)

The following is sample data – intended solely for illustrative purposes to demonstrate the comparison methodology; please replace this with actual project data.

Key project outcomes: +70% increase in daily production capacity; +7.2 percentage points improvement in first-pass yield rate; –67% reduction in labor hours per shift; –18% decrease in unit energy consumption.

The above figures – including production capacity, yield rate, and energy consumption – are illustrative data intended solely for demonstration purposes on the case study page; please replace them with your company's actual project data.

The entire process-from surveying to commissioning-was completed in just four months; after just one week of trial production, the line consistently met our production capacity requirements, with its coating uniformity significantly outperforming that of the previous production line. Since we handed over the entire production line to us, there has been continuous support provided regarding equipment, processes, and spare parts – which has greatly eased our concerns.

- [Customer Name] Production Manager [Customer Name] (Sample Review)

Your production line can be deployed from planning to actual operation within just four months. Simply submit your workpiece specifications and production capacity requirements – we will then arrange for our engineers to conduct an on-site survey and provide you with a customized design proposal and budget at no cost.