Yijin Hardware’s Technological Drive for ABB’s Production Innovation
As a global leader in robot manufacturing, ABB faced severe challenges in high-precision CNC machining component production. Relying on advanced CNC technology and a professional team, Yijin Hardware customized a precision CNC solution for ABB, achieving dual improvements in production efficiency and accuracy, significantly reducing the scrap rate, and strongly boosting market competitiveness.
Customer Background
ABB is a global leading electrical and automation technology enterprise, covering multiple fields such as power, industrial automation, and robotics. It has extremely high requirements for the precision and reliability of CNC machining. This cooperation aims to further improve the quality and efficiency of component processing and consolidate its leading position in the industry.
Analysis of Core Pain Points
Collapse of quality stability: 22% of components suffered tungsten carbide coating peeling due to excessive surface roughness (Ra0.7), leading to a monthly rework cost of 420,000 euros, and 3% of finished robots required complete machine recalls.
Out-of-control delivery cycle: The processing efficiency of NITRONIC 60 material was low, requiring specialized Matériaux d'usinage CNC expertise, causing a 9-day delivery delay, 4 shutdowns of the final assembly line, with a single loss of 3 million euros, and the quarterly order fulfillment rate plummeted to 78%.
Imbalance of cost-benefit: The processing cost per component surged by 28%, the annual procurement cost exceeded the budget by 22%, and the profit margin dropped by 5 percentage points.
Ineffective Past Solutions
- Technical standard upgrade: Equipment aging resulted in processing accuracy only reaching IT8 grade (IT6 grade required).
- Supply chain integration: Tool life was shortened to 4 hours, and processing efficiency decreased by 18%.
- Strategic sourcing substitution: Unit cost soared to 2.3 times, and delivery cycle was extended to 21 days.
Cooperation Opportunity and Decision Core
Building on the core opportunity identified, both teams have outlined a clear framework to guide their collaboration, ensuring alignment on objectives, resources, and timeline.
Cooperation Reach Path
ABB’s technical team discovered Yijin Hardware’s official website technical whitepaper through Google search, combined with LinkedIn technical articles and positive reviews on the Trustpilot platform, leading to the first technical docking.
Decision Influencing Factors
Digital Twin Validation: The cloud simulation system’s data simulation and actual sample error ≤ 3%.
Dynamic Tolerance Control: Supports ±0.015 mm tolerance online query, remote monitoring of flatness ≤ 0.02 mm.
Online turnover: Order response time compressed to 4 hours, digital process documents 72 hours faster than the industry.
Full-cycle service: 24-hour data query, fault response ≤ 1.5 hours.
Customized Solutions and Technological Innovations
By leveraging a modular approach that blends state-of-the-art machinery with smart tooling and adaptive process control, we deliver bespoke manufacturing solutions precisely tuned to each customer’s specifications.
Technical and Process Architecture
Our process framework is built around a unified control platform that seamlessly integrates digital monitoring, automated workflows, and modular machine layouts to maximize efficiency and traceability.
Core Equipment Configuration
German DMG Usinage CNC à 5 axes center, spindle speed 42,000rpm, positioning accuracy ±0.008 mm.
Swiss GF electric discharge forming machine, ensuring hole system position accuracy ≤ 0.01 mm.
Tool Technology Innovation
Japanese Kyocera CBN ceramic tools, lifespan 12 hours/edge (traditional only 4 hours).
Tool monitoring system real-time monitors wear, automatically changes tools when exceeding 0.1 mm.
Material Processing Technology
Rough machining: 150m/min + low-temperature MQL lubrication, removing 90% of the allowance.
Semi-finishing: 180m/min + thermal deformation compensation, correcting spindle thermal elongation ≤ 0.005 mm.
Finition : 200m/min high-speed milling, rugosité de la surface reduced to Ra0.35.
Software and Automation Systems
- HyperMill 2024 SP2 software, cutting efficiency increased by 35%
- AI cutting parameter decision system, processing stability increased by 60%.
- Digital twin model, predicting part deformation error ≤ 0.008 mm.
Customized and Innovative Technologies
Leveraging cutting-edge material science and smart automation, our tailored technology suite drives exceptional precision, flexibility, and throughput across every stage of production.
Fixtures and Jigs
- Dual-station thermal control tooling: Carbon fiber fixture controls temperature ≤ 80℃, clamping deformation ≤ 0.005 mm
- Electromagnetic induction jig: Adsorption force 12 N/cm2, clamping efficiency increased by 70%.
Processing Technology Innovations
- Ultrasonic vibration cutting: Cutting force reduced by 38%, tool wear rate decreased by 55%, continuous processing for 40 hours without tool change.
- Laser shock peening: Coating bond strength increased by 42%, salt spray test 1000 hours peeling area < 1%.
Conception pour la fabrication
- Structural topology optimization: Processing efficiency increased by 6 times, avoiding surface micro-cracks.
- Dynamic tolerance matching: Qualified processing area expanded by 30%, tool life extended by 40%.
Quality Control System
An end-to-end quality control framework combines real-time monitoring with rigorous batch inspections to catch anomalies at every stage and drive continuous process improvement.
Precision Detection and Tolerance Control
Online detection: Triggers tool wear detection every 3 pieces, tolerance stabilized at ±0.015 mm.
Offline measurement: CMM detects 21 key dimensions, CPK ≥ 1.67.
Special Detection Technologies
Coating bond strength test: Pull-out strength ≥ 50MPa, cross-cut test grade 0.
Non-destructive testing: Ultrasonic testing sensitivity Φ0.3 mm, micro-crack rate reduced to 0.3%.
Quality Management Certification
ISO 9001:2015, ISO 14001:2015 certified, compliant with VDA 6.3 standards.
Data security certified by ISO 27001, AES-256 encrypted transmission.
Quantifiable Success Results
By tracking key performance indicators across operations, quality, and financial metrics, we can clearly demonstrate the substantial gains achieved through our optimized processes and technologies.
Efficiency Improvement
- Single-piece processing time reduced from 75 minutes to 28 minutes (↓62.7%), and the delivery cycle shortened from 21 days to 9 days.
- Tool life increased to 12.4 hours/edge, equipment utilization rate increased from 55% to 89%, OEE increased from 62% to 88%.
- Tool cost saved 2.37 million euros/year, monthly power consumption reduced by 18,000 kWh.
Quality Improvement
- Coating non-conformance rate reduced from 18% to 0.8%, salt spray test peeling rate reduced to 0.
- Surface roughness reached Ra0.35 (12.5% exceeding requirements), key dimension CPK increased to 1.72 (30% exceeding the industry).
Business Impact
- Procurement cost decreased by 28%, annual savings of 12 million euros, rework cost ↓91.4%.
- Inventory turnover rate increased from 4.2 times/year to 7.8 times/year, production capacity increased by 35,000 robots.
- Automotive industry market share increased from 18% to 22% thanks to advanced automotive CNC machining, annual new revenue 170 million euros.
Senior Customer Evaluations
- Jens Schmidt, Director of Technology R&D: Ultrasonic vibration cutting enables process integration, thermal deformation compensation controls precision fluctuation ≤ 0.01 mm.
- Maria Garcia, Vice President of Global Procurement: Annual savings of 12 million euros, emergency order delivery cycle compressed to 5 days.
- Thomas Braun, Director of Supply Chain Operations: No peeling in salt spray test, inventory turnover rate increased by 85.7%.
Conclusion and Action Initiatives
Yijin Hardware has cracked the NITRONIC 60 processing problem through CNC technological innovation, achieved dual breakthroughs in efficiency and accuracy, saved ABB 12 million euros in annual procurement costs, and helped win high-end customer bids.
Free process diagnosis: Get a customized solution within 48 hours (including cutting parameter simulation).
Download technical whitepaper: Visit ABB Case for the full process guide.
“There are no unbreakable material barriers, only unactivated process possibilities through innovation.” — Thomas Braun, Director of Global Supply Chain Operations, ABB
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