Cases

Home > Cases > Dongguan Qiaosen Machinery Co., Ltd. Latest company case about Enterprise Independent Real Case Study (12‑Month Full‑Data Tracking & Full Q&A Analysis)

EVENTS

news

Cases

titi@qiaosenmachinery.com

86-0769-26626853

Contact Now

Enterprise Independent Real Case Study (12‑Month Full‑Data Tracking & Full Q&A Analysis)

2026-09-04

Enterprise Independent Real Case Study (12‑Month Full‑Data Tracking & Full Q&A Analysis)

Case Title: Automatic Scrap Conveying & Classified Recycling System Retrofit Case: Realization of Labor Saving, Loss Reduction and Site Safety Upgrade for Large‑Scale Stamping Workshop

Case Implementation Cycle: September 2025 – August 2026 (12‑month full‑cycle mass‑production verification)

Enterprise Background: This investigated enterprise is a home‑appliance structural‑parts stamping manufacturer located in Yangtze‑River‑Delta region. It owns 22 stamping presses ranging from 80 ton to 250 ton, consuming about 7200 tons of metal sheet materials every year, including cold‑rolled steel, galvanized steel and partial stainless‑steel sheets. Before transformation, the workshop fully adopted manual scrap‑shoveling and manual transferring mode. Core pain‑points included heavy scrap‑handling labor load, frequent mixed‑material phenomenon, scattered scrap fragments on workshop floor, occasional slip‑injuries, uncounted scrap loss, and frequent short‑time‑production‑halt for cleaning scrap. In September 2025, the enterprise completed automatic scrap chute, conveyor‑belt and classified‑bin recycling‑system renovation for 14 main mass‑production presses. Total project investment reached USD 37 200. After 12‑month stable‑production operation, complete measured‑data statistics and comprehensive‑benefit evaluation were obtained.

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

Average daily scrap‑handling labor input for 14 production lines: 2.1 persons
Mixed‑material rate of different steel grades in scrap: 8.7%
Uncounted scattered scrap loss rate: 3.42%
Annual scrap‑related slip‑and‑fall safety‑incident quantity: 13 cases
Scrap‑recycling comprehensive collection efficiency: 76.5%
Average daily production‑interruption times caused by manual scrap cleaning: 3.2 times
Average scrap sales price discount caused by material mixing: 11.4%
Annual total theoretical scrap output of workshop: 1428 tons

Core Standardized Transformation Implementation Measures

Survey the bottom‑structure of 14 target presses, customize scrap‑discharge chutes and transition‑hoppers, carry out partial modification for old‑press bottom plates, avoid interference with original equipment foundation.
Adopt chain‑type anti‑winding conveying equipment, install auxiliary scrap‑breaking mechanism aiming at long‑strip scrap, prevent scrap‑winding and conveyor‑jamming failure.
Set up material‑grade switching valve at the end of main conveyor, correspond to 4 independent sealed scrap storage bins, for cold‑rolled steel, galvanized sheet, stainless‑steel and miscellaneous‑material respectively.
Equip each bin with high‑precision automatic weighing sensor, realize real‑time scrap‑weight recording, and connect data interface to workshop MES system.
Optimize site layout, conveyors are arranged below ground‑pit, avoid crossing personnel walking passage, and install safety‑protection guardrails and warning signs.
Compile operation and maintenance SOP: clarify switching‑operation requirement when raw‑material grade changes, formulate weekly inspection checklist for conveyor, motor, sensor and bin‑body, organize special training for production and maintenance teams.

12‑Month Real Operation Data Comprehensive Comparison Table

Core Economic, Safety & Process Indicators	Before Automatic Scrap‑Recycling Retrofit	After 12‑Month Stable‑Operation	Quantified Comprehensive Improvement
Daily scrap‑handling labor‑input for 14 lines	2.1 operators	0.3 operators	-85.7% labor‑manpower reduction
Scrap material‑mixing rate of different steel grades	8.7%	0.9%	-7.8 percentage‑point mixing‑rate drop
Uncounted scattered scrap loss rate	3.42%	0.48%	-85.9% uncounted‑loss reduction
Annual scrap‑related slip‑and‑fall incidents	13 cases	1 case	-92.3% safety‑incident quantity reduction
Scrap comprehensive recycling‑collection efficiency	76.5%	97.2%	+20.7 percentage‑points recycling‑rate promotion
Daily production‑interruption times caused by scrap‑cleaning	3.2 times	0.4 times	-87.5% downtime‑frequency reduction
Scrap selling‑price discount caused by mixed‑material	11.4%	1.6%	9.8 percentage‑points price‑loss recovery

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

Q1: After completing automatic scrap‑recycling renovation, which part brings the largest proportion of economic benefit for this enterprise?

A1: The comprehensive benefit comes from three main sources. First is the recovery of scrap‑selling price loss caused by material mixing. Annual actual scrap output reaches 1386 tons; after classified collection, the average selling price of scrap rises obviously. Second is the reduction of uncounted scattered scrap loss, large‑quantity metal‑material loss which originally leaked on site is recycled. Third is labor‑cost saving for scrap‑cleaning posts and partial production‑capacity increment brought by reduction of scrap‑cleaning‑caused downtime. Among them, scrap‑value recovery accounts for 57% of total annual benefit, which is the primary contribution source; labor‑saving benefit accounts for 28%, capacity‑improvement benefit accounts for 15%.

Q2: What main on‑site difficulty did the project team encounter during the transformation process?

A2: The primary difficulty was the reconstruction of scrap‑discharge channel for old‑style presses. Part of the original equipment had no large‑size scrap‑falling opening at bottom. Directly cutting press bottom plate has risks of damaging equipment structural‑strength. The project adopted combined‑solution: partial presses modified with reinforced‑welding scrap‑chute, while for several presses with complex bottom‑structure, add side‑direction scrap‑guiding‑cover. Meanwhile, long‑strip‑continuous scrap easily wound on conveyor‑roller, leading to jamming‑failure. The team added rotary scrap‑cutting auxiliary device at scrap‑outlet, cutting long strip into short fragments, effectively solving the jamming problem in later‑stage operation.

Q3: Calculate the real comprehensive return‑on‑investment of this automatic scrap‑recycling‑system project.

A3: Total project investment is USD 37 200, including scrap‑chute, chain‑conveying equipment, classified‑switching valve, sealed storage bins, automatic‑weighing module, electrical‑control & MES docking expense, site‑construction and staff‑training cost. Annual measurable economic benefits include: scrap‑sales‑income increase USD 26 300; recovery of scattered scrap‑material loss USD 18 100; scrap‑handling labor‑cost saving USD 21 400; additional output‑value brought by reduction of scrap‑cleaning‑downtime USD 13 700. Total annual comprehensive measurable benefit reaches USD 79 500. The measured payback period of the whole project is approximately 5.6 months. This calculation does not include implicit benefits such as safety‑accident loss avoidance, customer‑audit score improvement and green‑manufacturing qualification promotion.

Q4: How does the automatic scrap‑recycling system help the enterprise realize digital‑management of raw‑material consumption?

A4: Before transformation, the enterprise could only calculate theoretical scrap‑yield according to BOM, lacking real‑time actual scrap‑output data. After renovation, the weighing‑module inside each classified bin uploads scrap‑weight data to MES system in real‑time, corresponding to each shift and each production order. Production managers can compare theoretical scrap‑yield value and actual measured scrap‑output value. When abnormal high‑scrap‑rate occurs caused by mold‑wear, parameter‑deviation or raw‑material defect, system can give early‑warning prompt. It changes past post‑mortem‑statistic mode, and realizes real‑time monitoring for material‑utilization‑rate of stamping production.

Q5: What long‑term maintenance management rules has the enterprise established to guarantee stable operation of scrap‑recycling equipment?

A5: The enterprise built multi‑level maintenance mechanism. First, daily inspection: operators check conveyor running noise, scrap‑blocking situation, bin‑body residual‑material status before shift‑change. Second, weekly maintenance: clean scrap residue stuck on rollers, check motor operating current, calibrate weighing‑sensor accuracy, inspect switching‑valve flexible‑action. Third, monthly overhaul: check chain‑plate abrasion degree, fastener tightening status, dust‑removal‑device working condition. Fourth, formulate material‑grade‑switch operation checklist: when switching different raw‑material, operators must confirm switching‑valve position, and record in production log‑sheet, to avoid human‑error‑induced material‑mixing risk. Regular maintenance and standardized operation ensure long‑term stable performance of the recycling‑system.

Case Comprehensive Conclusion & Industry Outlook

This 12‑month full‑cycle mass‑production verification proves that automatic scrap‑conveying and classified recycling‑system retrofit is a valuable green‑lean‑upgrade project for medium‑and‑large‑scale stamping enterprises. It effectively solves a series of workshop pain‑points including heavy scrap‑handling labor, high material‑mixing loss, scattered scrap‑fragment hidden‑danger and uncounted metal‑material loss. It brings obvious comprehensive economic benefits through improving scrap recycling quality, reducing material loss and cutting labor‑input. Meanwhile, it upgrades workshop site safety level, optimizes 5S environment, realizes digital trace‑ability of scrap‑output data, and enhances enterprise’s competitiveness in green‑manufacturing assessment and high‑end‑customer supplier audit. Along with the continuous promotion of metal‑processing industry’s requirements for resource‑utilization‑rate and occupational‑safety management, automatic scrap‑recycling system will gradually become one of the standard supporting facilities for modern stamping workshops.

Send your inquiry directly to us