Views: 0 Author: Site Editor Publish Time: 2025-12-18 Origin: Site
When Foshan Dingyi Industrial Technology Co., Ltd. (hereinafter referred to as "Dingyi Industrial") became Midea Group's first full-range BPO partner, this collaboration was not just a business alliance—it marked Dingyi Industrial's critical leap toward becoming a "smart manufacturing benchmark." As a core supplier to Midea, a leading Chinese kitchen appliance enterprise, Dingyi Industrial has built an efficient, flexible microwave oven production system driven by vertical integration and digital management. Its development model, centered on "modular design, full-process quality control, and technology standard-driven innovation," is redefining efficiency and quality boundaries in microwave oven manufacturing.
Dingyi Industrial's production system is structured around "three core stages + five intelligent production lines", balancing functional integration with manufacturing feasibility to enable flexible switching between "multi-variety, small-batch" and "large-scale, standardized" production:
Raw Material Preparation: Precision Material Selection and Preprocessing
Dingyi Industrial has established a raw material traceability system, with core materials (e.g., SPCC cold-rolled steel, SPCD deep-drawing steel, SGCC galvanized steel, and tempered glass) sourced from top suppliers like Baosteel and Xinyi Glass. This ensures compliance with national standards such as GB/T 11253 and GB/T 2518. A nano-treatment line is used for preprocessing, applying nano-coatings to metal surfaces to enhance corrosion resistance by 30% (passing 72-hour salt spray tests) and address the common pain point of "rust-prone, hard-to-clean" traditional microwave ovens.
Core Component Processing: Automated Equipment Replaces Manual Labor
Dingyi Industrial has invested nearly 100 million yuan in an automated processing cluster, achieving "unmanned operation" for key processes:
Stamping Process: High-speed precision stamping machines (300 strokes/minute) form SPCC, SPCD, and SGCC sheets into microwave oven liners, outer casings, and chassis with dimensional errors ≤ 0.1mm.
Laser Cutting Process: Laser cutters create custom-shaped parts (e.g., vent holes for microwave doors) on galvanized and cold-rolled steel with precision ≤ 0.05mm and burr-free edges.
Welding Process: Laser welders and resistance welders join stamped parts (e.g., liner seams, outer casing frames) to meet GB/T 19804 standards for weld strength and leak-proof performance.
Precision Machining Center: Independently produces core components like magnetron brackets and turntable motor bases to ensure assembly accuracy.
Assembly and Debugging: Modular Assembly + Intelligent Inspection
Dingyi Industrial's intelligent assembly line uses a "modular splicing" model, enabling quick assembly of heating, control, and door modules via standardized interfaces—reducing single-unit assembly time to 15 minutes. An AI visual inspection system automatically identifies component misalignment and loose wiring with 99.9% accuracy. Each product undergoes "10 heating tests + 24-hour continuous operation tests" to ensure microwave leakage ≤ 5mW/cm² (well below the national standard of 10mW/cm²).
Dingyi Industrial's closed-loop production network—stamping line, laser cutting line, welding line, intelligent assembly line, and automated storage system—optimizes efficiency. The automated storage system uses WMS (Warehouse Management System) for intelligent sorting of raw materials and finished products, increasing inventory turnover by 40% and reducing work-in-progress costs.
As the "heart" of core component processing, Dingyi Industrial's laser cutting factory is equipped with dozens of Hongshan laser cutters (1000W–6000W) and CNC bending machines for "zero-error" processing of cold-rolled and galvanized steel:
Cutting Precision: ≤ 0.05mm error for complex parts (e.g., vent arrays on microwave doors), supporting customization.
Efficiency: Single laser cutter processes 120 sheets/day—3x faster than traditional shears.
Bending Accuracy: CNC bending machines (servo motor + hydraulic system) achieve ≤ 0.5° angle error, ensuring seamless assembly of outer casings and doors.
Dingyi Industrial's spraying factory uses fully automated electrostatic spraying lines to apply both powder coating and oil coating to cold-rolled and galvanized steel:
Powder Coating: Epoxy powder for outer casings and chassis, cured at 180°C for 20 minutes—achieving 0-level adhesion (no peeling) per GB/T 9286 and 3H scratch resistance.
Oil Coating: PU high-gloss paint for control panels and door handles, cured via "electrostatic spraying + UV curing" for ≥ 90° gloss and 4-level yellowing resistance (no discoloration after 500 hours).
Environmental Compliance: Activated carbon adsorption + catalytic combustion system reduces VOC emissions to ≤ 30mg/m³ (far below the national standard of 120mg/m³).
Customization: Supports custom colors (e.g., matte black, ivory white) with uniform coating thickness (60–80μm).
As Midea's first full-range BPO partner, Dingyi Industrial's BPO factory is the "core hub" of microwave production, with an annual capacity of 130,000 door assemblies and 150,000 cavity assemblies:
Modular Flexible Lines: Supports custom function combinations (e.g., grilling + steaming) with line changeover time ≤ 30 minutes.
Intelligent Scheduling: APS (Advanced Planning and Scheduling) system allocates resources by order priority, ensuring "48-hour delivery for small batches, 72-hour delivery for large batches."
Collaborative R&D: Joint lab with Midea’s R&D team for early-stage product design (e.g., structural optimization of smart inverter microwaves) to achieve "design for manufacturing."
Dingyi Industrial's welding line uses 20 laser welding robots and resistance welders for key components like microwave liners and outer casing frames:
Welding Precision: Laser welds with ≤ 0.2mm width error, no pores or cracks—ensuring liner sealing (microwave leakage ≤ 5mW/cm²).
Efficiency: Single robot welds 300 components/day—5x faster than manual welding.
Quality Traceability: MES system records welding parameters (current, voltage, time) for full process traceability.
Dingyi Industrial's automated storage system uses AS/RS (Automated Storage and Retrieval System) + AGV robots for "unmanned" storage and handling:
Storage Capacity: Holds 100,000 raw material units and 50,000 finished products—3x space utilization of traditional warehouses.
Sorting Efficiency: AGV robots sort at 1.2m/s with 100% accuracy, increasing inventory turnover by 40%.
Intelligent Scheduling: WMS-ERP integration enables end-to-end logistics visualization from "raw materials to finished products."
A core competitive advantage of Dingyi Industrial is the deep integration of ERP, MES, and PLM systems, enabling full-process data visualization from order to delivery:
ERP System: Integrates sales, procurement, production, and finance data to quickly decompose orders (e.g., 1,000-unit microwave orders are split into component procurement requirements within 1 hour).
MES System: Real-time production monitoring and traceability (e.g., alerts for abnormal welding current and process locking).
PLM System: Manages product lifecycle data and syncs with Midea’s PLM system for real-time design changes (e.g., adjusting heating power parameters within 24 hours).
Additionally, Dingyi Industrial uses digital twin technology to simulate production processes, optimizing equipment layout and节拍—for example, identifying bottlenecks to increase efficiency by 15%.
A: Dingyi Industrial uses modular design + digital twin technology:
Modular Design: Microwaves are split into independent modules (heating, control, door) with standardized interfaces, supporting customization while ensuring manufacturing repeatability.
Digital Twin Technology: Virtual simulations verify module compatibility (e.g., heating-control linkage) during design to avoid "unmanufacturable" products. For example, optimizing liner shape via airflow simulation improved heating uniformity (temperature difference ≤ 5℃) and reduced mold costs.
A: Dingyi Industrial uses automated equipment + full-process quality control:
Reduce Labor Costs: Automated equipment cuts labor share from 30% to 15% (e.g., laser cutting factory output is 5x that of traditional factories).
Reduce Rework Costs: Full-process quality control (raw material → component → assembly → finished product inspection) lowers defect rates to < 0.5% (e.g., AI inspection identifies misalignment early).
Optimize Supply Chain Costs: Strategic alliances with Baosteel and Xinyi Glass reduce raw material costs by 10% while ensuring quality stability.
A: Dingyi Industrial's BPO model delivers "technology synergy, scale effects, and standard-driven improvement":
Technology Synergy: Midea’s R&D system injects cutting-edge design concepts (e.g., smart inverter technology, HMI interfaces) to upgrade "functional integration" to "experience integration."
Scale Effects: Midea’s large orders drive capacity expansion (annual output > 500,000 units) and lower marginal costs via automation.
Standard-Driven Improvement: Midea’s strict supply chain standards (e.g., component precision ± 0.1mm, 100,000-cycle product life) force Dingyi Industrial to build a full-process quality control system.
A: Dingyi Industrial will focus on "smart interaction + green manufacturing":
Smart Interaction Upgrade: Integrate AI voice control and HarmonyOS ecosystem connectivity for smart home integration (e.g., remote heating via mobile app).
Green Manufacturing Transformation: Promote solar power (annual generation > 500,000 kWh) and wastewater recycling (90% utilization) to align with "dual carbon" goals.
A: Dingyi Industrial plans to build a "Microwave Oven Industry Innovation Center" to support SMEs with:
Technical Consulting: Share modular design and digital management expertise.
Equipment Sharing: Open laser cutting and spraying factories to reduce SMEs' capital investment.
Standard Output: Participate in formulating Smart Manufacturing Standards for Microwave Ovens to drive industry-wide upgrading.
Dingyi Industrial's development model is a classic case of "collaboration-driven empowerment, technology innovation, and management upgrading". From BPO collaboration with Midea to building an independent smart manufacturing system, Dingyi Industrial proves that manufacturing competitiveness stems not just from scale and cost, but from precise alignment of "user needs" and "technical feasibility." As the microwave oven industry shifts toward "smart, eco-friendly, and customized" solutions, Dingyi Industrial's model will serve as a reference for more manufacturers—reshaping production with digitalization, leading the industry with standardization, and defining the future with innovation.
