Training Chair Parts Delivery for Hanoi Welding Workshop

О проекте

Background

A chair manufacturing workshop in Hanoi, equipped with multiple welding stations and a separate component storage area, entered the ramp-up phase for training chair assembly in 2013. The site required chair frames and seat shells matched to the existing welding, storage and handling pace, for component preparation ahead of batch assembly.

Requirements and challenges

• Welding station fit: Chair frames must hold a fixed position after entering the welding area. Dimensional deviation exceeding 2 mm in parts would directly affect seat shell alignment and weld consistency.
• Storage stacking limits: The component storage area uses tiered racking. Chair frames and seat shells must be stacked in a uniform orientation, with stack height constrained by shelf spacing, without slipping or crush damage.
• Assembly pace constraints: The site operates on pull-based replenishment by workstation. Incoming parts batches must align with the assembly schedule to avoid backlog in the component area or idle stations waiting for material.

Specification and solution

• Single stock training chair parts model: One model in this category is listed on the website. We configured it in batches without introducing non-standard variants, reducing on-site identification and changeover costs.
• Separate palletised packaging for frames and shells: Chair frames were palletised in welding orientation, and seat shells layered by stacking direction. Per-pallet quantities matched shelf capacity for direct forklift placement onto racking.
• Pre-shipment dimensional check: Sampling inspection was carried out against welding positioning datums before dispatch, with focus on mounting hole spacing and edge profile, ensuring parts entered the workstation without secondary rework.

Delivery and outcome

• Arrived in Hanoi ahead of the original schedule for entry into the component storage area.
• Sampling pass rate: 98% pass rate on critical frame positioning dimensions, with no welding rework caused by dimensional deviation.
• Racking efficiency: Time per pallet put-away in the component area dropped from approximately 25 minutes to 12 minutes, with forklift trips reduced by nearly half.

Client feedback: The parts went straight onto the racks after arrival. The welding team never waited for material, and there was no stacking damage to the seat shells.