DAILY UP FURNITURE
Projektübersicht
Background
The project is located in an office chair component production workshop in Zhongshan, where line reorganisation and tooling upgrades began in 2013. The line mainly assembles office chair bases, gas lifts and armrests. The original work area had scattered material堆放, inconsistent station jigs and crossing transfer paths, which affected assembly cadence and site management.
Requirements and challenges
- Jig positioning accuracy: The interface between bases and gas lifts requires stable clamping, with jig flatness controlled within 0.5 mm. Any assembly offset would directly affect the smoothness of the finished chair's rotation.
- Mixed-line material management: Three component types are produced on the same line. Racks needed clear zoning by base, gas lift and armrest to prevent different batches from being mixed at the assembly bench.
- Station spacing and transfer: Workshop aisles are narrow. The combined footprint of assembly benches and racks had to leave at least 900 mm of clearance for forklift and pedestrian access.
Specification and solution
- Standard assembly benches: Selected the medium-duty model from our 4 standard office chair component assembly benches, with anti-scratch matting on the work surface and adjustable clamping jigs to suit base and gas lift press-fit stations.
- Zoned storage racks: Used three-level beam-type component racks, each level divided by part type with card-insert label slots. The bottom level includes a returnable bin slide-in position to reduce walking distance for material retrieval.
- Quick-change jig design: The armrest assembly station uses a quick-change jig plate with locating pins, eliminating recalibration during changeovers and supporting small-batch, multi-SKU switching.
Delivery and outcome
- Quantity delivered: 41 tooling items in total, including assembly benches, racks and jigs, all corresponding to 4 standard catalogue models with no custom modifications.
- Installation period: On-site marking, positioning, installation and commissioning were completed without interrupting normal production.
- Measured improvement: After relaying out the assembly benches and racks, material retrieval distance for the three component types was reduced by approximately 35%, and station changeover time dropped from an average of 18 minutes to under 9 minutes.
Client feedback: The rack zoning is clear, the jigs line up correctly, and changeovers take half the time they used to. Workers no longer have to walk back and forth looking for materials.
