EN
Transformer Production — Complete Assembly Lines for Power Distribution Equipment
Project Overview
We delivered a turnkey transformer production line solution for an electrical equipment manufacturer. The company mainly supplies distribution transformers for utility and industrial scenarios.
Challenge
The client suffered from fragmented and inefficient production:
Heavily manual operations, unsmooth material flow and excessive WIP inventory
Unstable quality in core winding and lamination processing
Reliance on scattered suppliers, leading to frequent material shortages
Lengthy model changeover and low production flexibility
Heavily manual operations, unsmooth material flow and excessive WIP inventory
Unstable quality in core winding and lamination processing
Reliance on scattered suppliers, leading to frequent material shortages
Lengthy model changeover and low production flexibility
Our Solution
We built a highly automated and integrated production system with consolidated supply support:
Automated core processing for cutting, stacking and welding
High-precision programmable coil winding equipment
Continuous flow-line assembly with inline automatic testing
Integrated one-stop supply of key raw materials and components
Modular quick-change tooling to shorten model switching within 30 minutes
Automated core processing for cutting, stacking and welding
High-precision programmable coil winding equipment
Continuous flow-line assembly with inline automatic testing
Integrated one-stop supply of key raw materials and components
Modular quick-change tooling to shorten model switching within 30 minutes
Results
Productivity gain: Overall production throughput increased by 70%
Inventory reduction: WIP reduced by 55% through improved flow line design
Quality improvement: First-pass yield improved from 89% to 97%
Supply reliability: 100% on-time material delivery through integrated supplier network
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