As the automotive industry’s demands for quality and production capacity of seat safety components continue to rise, FSDL’s existing resistance welding process for seat parts can no longer meet current requirements for mass production, quality control, and traceability. Therefore, an upgrade collaboration on automated resistance welding equipment has been initiated. The original process faced the following key challenges:

1. Production efficiency bottleneck: The existing welding equipment operates at a slow cycle time, failing to meet high-volume production demands. Additionally, low equipment utilization rates make it difficult to support large-scale, continuous 24/7 three-shift operations.
2. Lack of error-proofing capability: The original equipment lacks robust error-proofing controls, making it unable to effectively detect missing or incorrect part installations, nor to reliably intercept defective products. This increases the risk of defect leakage, compromising the safety performance of seat components.
3. Insufficient quality traceability: The previous production process lacked parameter traceability—welding parameters could not be linked and stored with individual parts, and changes in parameters were not recorded. This fails to meet the automotive industry’s stringent traceability requirements, making root cause analysis difficult when quality issues arise.
4. Limited production flexibility: The original equipment suffers from inefficient changeover times. Switching between different seat part specifications requires extensive manual adjustments, making it unsuitable for small-batch, multi-variety production needs.
5. Inconsistent quality control: The existing equipment has inadequate welding quality management capabilities, resulting in unstable output and high defect rates. Significant fluctuations in welding parameters lead to frequent welding defects, while high equipment downtime further undermines production stability.