Cases

Home > Cases > Dongguan Qiaosen Machinery Co., Ltd. Latest company case about 12-Month Green Production & Secondary Defect Elimination Practice for High-Speed Precision Stamping Workshop

EVENTS

news

Cases

titi@qiaosenmachinery.com

86-0769-26626853

Contact Now

12-Month Green Production & Secondary Defect Elimination Practice for High-Speed Precision Stamping Workshop

2026-09-01

Full-Line Oil Mist Purification System Upgrade Case: 12-Month Green Production & Secondary Defect Elimination Practice for High-Speed Precision Stamping Workshop

Case Implementation Cycle: November 2025 – August 2026 (10-month full-cycle stable operation verification)

The case enterprise is a professional high-speed precision stamping manufacturer in Jiangsu, mainly producing home appliance appearance structural parts and 3C electronic metal accessories. The workshop has 21 high-speed stamping lines of 60T–180T, with long-term continuous shift production. Before transformation, the workshop relied entirely on traditional exhaust fans for ventilation. The air was turbid with obvious oil mist floating, resulting in frequent product surface oil contamination defects, easy mold oil dirt blockage, high post-coating rework rate and long-term environmental non-compliance risks. In November 2025, the enterprise completed full-station industrial oil mist purification system installation and transformation, with a total project investment of USD 19,800. After 10 months of stable operation, comprehensive before-and-after data comparison and benefit verification were formed.

Real Baseline Data Before Transformation (November 2025 Official Workshop Statistics)

Workshop average oil mist concentration: 11.3 mg/m³
Oil mist-induced surface secondary defect rate: 2.18%
Monthly equipment electrical aging failures: 3.9 times
Mold cleaning and oil dirt removal cycle: 4 days
Post-process painting rework rate caused by oil residue: 1.43%
Annual environmental inspection hidden danger records: 5.8 times
Monthly workshop manual deep cleaning labor cost: USD 2,150
Monthly customer complaints about appearance foggy surface: 1.8 times

Core Standardized Transformation Implementation Measures

Remove all inefficient traditional exhaust fans, install targeted high-efficiency oil mist purifiers for each high-speed stamping station, and realize one-machine-one-purification independent treatment.
Adopt multi-stage filtration and electrostatic adsorption composite purification technology to realize precise capture of micro oil mist particles, with purification efficiency stabilized above 98%.
Equip waste oil recovery and collection device to realize centralized recovery and recycling of stamping lubricating oil, reducing oil material waste.
Optimize workshop air circulation layout to eliminate local oil mist dead corners and realize full-station clean air coverage.
Establish regular purifier cleaning, filter replacement and oil recovery SOP to ensure long-term stable purification effect and air quality standard compliance.

12-Month Real Operation Data Comprehensive Comparison Table

Core Quality, Environment & Economic Indicators	Before Oil Mist Purification Upgrade	After 10-Month Stable Operation	Quantified Comprehensive Improvement
Workshop oil mist concentration	11.3 mg/m³	1.6 mg/m³	-85.8% air quality improvement
Oil mist secondary surface defect rate	2.18%	0.24%	-89.0% appearance defect reduction
Monthly electrical equipment failure times	3.9 times	0.7 times	-82.1% equipment failure drop
Mold oil dirt cleaning cycle	4 days	28 days	+600% maintenance cycle extension
Post-painting rework rate	1.43%	0.21%	-85.3% coating quality loss reduction
Annual environmental hidden danger times	5.8 times	0 times	100% environmental compliance
Monthly workshop cleaning labor cost	USD 2,150	USD 620	-71.2% labor cost saving
Monthly appearance quality customer complaints	1.8 times	0.2 times	-88.9% customer complaint reduction

In-Depth Case Full Q&A (Project Actual Verification & Data Analysis)

Q1: Why can oil mist purification transformation greatly reduce appearance secondary defects without changing stamping process parameters?

A1: Most stamping appearance defects are not caused by stamping deformation, but by post-production suspended pollution. In the traditional production environment, floating oil mist continuously settles on the surface of parts during production and stacking, forming invisible ultra-thin oil films. These uneven oil films lead to poor surface gloss, foggy feeling and paint peeling after coating. After the purification system is fully opened, the air cleanliness of the workshop is greatly improved, and there is basically no floating oil mist particle settlement. The surface cleanliness of stamped parts is maintained stably, and the secondary pollution defect source is eliminated from the root, so the appearance qualification rate is significantly improved.

Q2: What was the biggest difficulty in the on-site installation and commissioning of the purification project?

A2: The biggest difficulty is the air volume matching and wind direction balance of multi-station dense production lines. In the initial stage of transformation, unreasonable local air volume setting led to unobvious purification effect in individual corner stations. The technical team adjusted the air suction angle and purification air volume one by one according to the stamping beat and oil mist generation volume of different equipment, eliminated air dead corners, and completed 72-hour continuous air quality monitoring and debugging. Finally, the oil mist concentration of the whole workshop was balanced and stable, reaching the standard comprehensively.

Q3: What is the actual comprehensive investment return of this oil mist purification transformation?

A3: The total project investment is USD 19,800. The annual comprehensive measurable benefits include: annual appearance rework loss saving USD 32,600, annual equipment maintenance cost saving USD 21,400, annual workshop cleaning labor cost saving USD 18,360, annual lubricating oil recycling benefit USD 9,800, and zero environmental penalty risk increment. The total annual comprehensive benefit reaches USD 82,160. The actual measured project payback period is only 2.89 months, with extremely high lean improvement value.

Q4: How does oil mist environmental upgrade improve the enterprise’s customer audit and green factory qualification?

A4: High-end 3C and home appliance brand customers have very strict requirements on production environment cleanliness and green manufacturing level. Before transformation, the turbid oil mist environment often led to audit deduction points and environmental risk warnings. After the purification transformation, the workshop air quality meets the national green factory standard, with complete environmental treatment facilities and monitoring records. The enterprise successfully passed the ISO14001 environmental management system re-audit, and the factory environment assessment score increased from 80.2 to 95.7, further consolidating the qualification of high-quality long-term suppliers.

Q5: What long-term maintenance and closed-loop management mechanisms has the enterprise established?

A5: The enterprise has built a full-cycle air quality management system. First, formulate weekly purifier cleaning and monthly filter replacement standards to ensure stable purification efficiency. Second, arrange special personnel to monitor workshop oil mist concentration daily and form air quality data reports. Third, regularly recycle waste lubricating oil to realize resource recycling and reduce material consumption. Fourth, take air quality qualification rate and equipment stable operation rate as team assessment indicators to ensure long-term stable green production effect.

Case Comprehensive Conclusion & Industry Outlook

This 10-month full-cycle mass production verification fully proves that oil mist purification system upgrading is an essential green transformation and hidden quality loss reduction project for modern stamping workshops. It thoroughly solves the long-term industry pain points of workshop oil mist pollution, product secondary contamination, accelerated equipment aging and environmental non-compliance. With low investment and short payback period, the project realizes simultaneous improvement of product appearance quality, equipment stability, workshop environmental level and customer satisfaction. In the future green manufacturing upgrading trend, oil mist purification and clean workshop management will become the basic threshold for stamping enterprises to undertake high-end appearance part orders and achieve sustainable standardized production.

Send your inquiry directly to us