Case Studies

Case Studies

Selected Hexin projects in the automotive, medical, and home appliance sectors. Each solution was tailored to the specific client, product, and project. The cases shown here are just a sample: Hexin has completed projects in numerous other industries—and the selection is constantly expanding.

Industries

Case Studies by Industry

Requirements vary depending on the client, product, and project. The following industries are featured in the case studies on this page—in addition, Hexin has completed projects in other industries as well.

Automotive

Seat assembly, sunroof, engines, EOL testing, wheels.

Medical

Precision assembly and large equipment with lead shielding.

Home appliances

Variant assembly with flexible switching.

Overview

Eight Cases at a Glance

Eight completed projects with documented key metrics. Each selection reveals the challenge, solution, and results.

Assembly line

Sunroof Line

120 s/unit cycle time
, 6-month lead time

Mixed-model assembly

Seat installation

43 s/unit cycle time
1,466 units per day

Engine Assembly

Engine Assembly

≤115 s/unit line cycle
≤90 s/unit station cycle

Subassembly

Wheel Assembly

18″ / 20″ wheel sizes
Multiple facilities worldwide

EOL & Testing

EOL testing

12 s/unit cycle time
Full-process data traceability

Fully automated assembly

Medical: Precision Assembly

5.5 s/unit cycle time
Fully automated from feeding to inspection

Heavy Equipment Line

Medical: Large Equipment

−50% space requirement
720 → 400 min processing time

Variant assembly

Home appliances

40 s/unit cycle time
Fully automatic end cap assembly

Case Studies in Detail

Challenge, Solution, Results

For each case, you can view the challenge, the solution, and the documented key metrics.

Challenge
New sunroof line featuring complex robotics integration, high-precision testing, and reliable coordination among multiple suppliers within a tight delivery window.
Solution
  • Bosch Transfer – Bosch transfer technology as the backbone of the production line.
  • ABB Robotic Adhesive Application – Robot-assisted adhesive application for consistent results.
  • Vision Inspection – Image Processing with a Traceability System.
  • Acoustic Test – Regular online acoustic testing.
Results
120 s/unit
Cycle time
6 months
Delivery time
Initial acceptance
passed
Challenge
A production line for the mixed production of two vehicle models, featuring high automation, full traceability, and quick changeovers.
Solution
  • Assembly and inspection stations – Automated assembly and inspection stations arranged in a row.
  • RFID Traceability – Individual item identification throughout the entire production line.
  • PLC Process Monitoring – Real-time data from every station.
  • Vision-based error prevention – Image-based poka-yoke inspection.
  • Force and Noise Testing – End-of-Line Functional Test.
Results
43 s/unit
Cycle time
1.466
pieces per day
18
Operator
Challenge
A flexible production line for multiple engine models, featuring mixed-model production, end-to-end traceability, and real-time visibility into production.
Solution
  • Automated stations – fully automated screwing and testing in sync with the production cycle.
  • AGV Material Handling – Automated guided vehicles supply the stations.
  • Dual Dashboards – Two production dashboards for line and plant views.
  • MES Integration – Traceability and Monitoring via MES.
Results
≤115 s/unit
service frequency
≤90 s/unit
Frequency of service
Scalable
for future models
Challenge
A more stable, efficient, and cleaner production process for small, high-precision medical components that were difficult to assemble by hand.
Solution
  • Four-axis robots – Coordinated robots for precise handling.
  • High-precision vision – image processing for position and quality control.
  • Laser welding – A clean joining technique for small components.
  • Integrated stations – feeding, assembly, welding, and inspection all in a single line.
Results
5.5 s/unit
Cycle time
Fully automatic
From feeding to testing
Higher
Yield & Stability
Challenge
The previous production process was fragmented, space-intensive, and time-consuming—and exposed operators to radiation during testing.
Solution
  • Lead-shielded tunnel structure – integrated radiation protection for operators.
  • Modular Drive System – Universal Pallets for Assembly and Testing.
  • Combined process – assembly and testing in a single production run.
  • Safe environment – protecting employees in the test area.
Results
−50 %
Space requirements
720 → 400 min
Processing time
+44 %
Efficiency
Challenge
Manual assembly by the customer resulted in inconsistent quality, low efficiency, and positioning issues due to parts being delivered in an irregular manner.
Solution
  • Robotic Pick-and-Place – Gripping and placing using robots.
  • Automatic feeding – Parts are fed automatically.
  • Secondary positioning – position correction prior to installation.
  • Pneumatic Assembly – Reproducible clamping force.
  • Variant switching – Quickly switch between product variants.
Results
40 s/unit
Cycle time
Fully automatic
End Cap Installation
Higher
Stability & Flexibility
Challenge
A high-precision production line capable of handling multiple wheel sizes with quick changeovers and consistent quality across global manufacturing sites.
Solution
  • 18-inch and 20-inch wheels – The line supports two wheel sizes.
  • Quick changeover – Fast switching between variants.
  • In-line inspection – Quality is checked at every step of the production line.
  • Replication Design – Designed for multiple international facilities.
Results
18″ / 20″
Wheel sizes
Multiple
Plants worldwide
Faster
Product Change
Challenge
A highly automated solution for precision assembly and final inspection, offering full traceability and consistent quality.
Solution
  • Material Handling – Seamless material flow between stations.
  • Robotic handling – Component handling using robots.
  • Plasma cleaning – Cleaning prior to joining or coating.
  • Online EOL Test – End-of-line testing on a regular basis.
  • PC Traceability – Data tracking via a PC system.
Results
12 s/unit
Cycle time
Fully automatic
Assembly & Testing
Seamless
Data traceability

Project in the works?

Inquiries that include details on the component, quantity, and industry will receive an initial response within 24 hours for DACH customers. We also implement projects within the timeframe specified by the customer. Estimated timeframes: approximately 4–6 months for projects at our main location in China; approximately 6–8 months for European projects.

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Production Systems