Since its founding in 2011, Guanli has rapidly risen over the past decade to become a high-quality enterprise integrating a complete upstream and downstream industrial chain, top product development talents, and excellent production and quality management. However, with the rapid expansion of the company, traditional management models can no longer support current development needs, and innovation is urgently required to meet challenges.

"Guanli has never stopped thinking about change. We realized the importance of digital transformation early on, but the specific path and direction have always been under exploration. After contacting ALSI, their team helped us identify the key point we should focus on now—equipment information. Mastering equipment information not only provides a scientific basis for production planning and business strategy adjustments, but also allows us to continuously optimize production processes, improve product quality, and reduce costs." According to the head of Guanli's IT department, this became the opportunity for Guanli and ALSI to join hands. After several in-depth discussions, the two parties finalized a cooperation plan.

Guanli currently operates three factories in Zhenhai District, Ningbo City, and Xinchang County, Shaoxing City. After multiple inspections, management found that the continuous growth of equipment information across the three factories has generated massive data flows. However, under traditional manual management, these valuable data could not be effectively aggregated and analyzed, leaving management unable to accurately grasp real-time production conditions. Key information such as the availability of each machine, the number of machines running normally or stopped daily, reasons for stoppages, and product yield rates were all unknown. Traditional manual control is not only inefficient but also error-prone and highly time-consuming and labor-intensive, posing a significant obstacle to the company's overall development.

Therefore, Guanli hopes to use ALSI's customized digital transformation solution to break the 'black box' state of equipment information. The ALS Jingzhi Lean Factory Cloud Platform Equipment Status Monitoring OEE System fully meets Guanli's needs. Based on real-time equipment status monitoring, it enables precise visualization and analysis of production progress, equipment availability, and stoppage reasons, thereby prescribing the right solution to establish a sound information management system and achieve intelligent, automated, and visualized production processes.

For a long time, the equipment availability of Guanli's Xinchang constant-temperature workshop was maintained at around 45%. Although management conducted multiple inspections, it was difficult to formulate effective improvement plans based solely on information provided by employees. After using the OEE system to analyze the Gantt chart of each machine's status, it was discovered that multiple machines were in a non-production state for extended periods due to frequent changeovers. Through joint discussion, Guanli adjusted the production orders in the workshop, optimized the production sequence for orders of the same product model, and fixed the product model to be produced on each machine. By July, the workshop's OEE had increased to 55%.

"Improving OEE has always been one of Guanli's key transformation goals, as it relates to equipment availability, equipment performance, and product yield. We had tried various methods before, but the results were not as expected. This system has significantly improved equipment availability and also opened up new lean production ideas for us."

- Head of Guanli IT Department

After the system went live, Guanli's management noticed an anomaly: the CNC vertical grinder (model: ER-VGM1350-X2) in the Xinchang constant-temperature workshop had high availability during the day shift, but a significant drop occurred during the night shift. After in-depth investigation, it was found that the workshop operates 24 hours a day, and the night shift also has orders to produce. The problem was that most of the skilled operators for this equipment were assigned to the day shift, while the night shift mostly consisted of novices, leading to the significant difference in availability.

"Thanks to the system, we would hardly have detected this otherwise. Previously, we only knew the total output of the equipment over 24 hours, but had little knowledge of the specific output during different time periods. Now we have adjusted the shift arrangement, assigning some skilled workers to the night shift, and recruited new employees based on data analysis results. It is expected that the output of day and night shifts will be roughly balanced in the future."

- Head of Guanli Production Department

Paving the way for grand roads, forging paths through brambles. After overcoming the pains of transformation, Guanli has now built a cockpit for visualized equipment data management, breaking the data "black box" and processing collected data in an intuitive, visual, and concrete manner, effectively combining indicator analysis with decision-making sites, thus accelerating onto the fast track of development with new momentum.

"During the project implementation, we also encountered some difficulties. For example, some older employees were initially worried about operations and other issues. However, the ALS system is very easy to operate; basically, it can be mastered and put into use in less than a day. In addition, the project team also verified the accuracy of each machine's status data on site to ensure that the collected equipment working status information was correct. They also helped us review the equipment-related data daily and provided timely feedback. The management team highly commended the services provided by the ALS team."

- Head of Guanli IT Department

The road is long and arduous, but with action, we will reach our destination. The successful implementation of this project has strengthened Guanli's determination to continue advancing digital transformation and has given it a blueprint for standing out among thousands of enterprises. Facing the rapidly changing market landscape, ALSI will do its utmost to assist every partner in integrating their management models, identifying breakthroughs, and integrating into advanced industrial environments and rich ecosystems with a new posture, enhancing core digital competitive advantages and helping enterprises achieve long-term stable and sustainable development.

About ALSI

ALS System Integration (Dalian) Co., Ltd. (referred to as "ALSI") is a wholly-owned subsidiary established in China in 2005 by Alps Alpine Group (founded in 1948). It is the Secretary-General Unit of Dalian Intelligent Manufacturing Industry Innovation Alliance and a "Specialized, New, and Distinctive" enterprise in Liaoning Province. With over 30 years of deep cultivation in intelligent manufacturing in industries such as automotive components, electronics, and mechanical processing, ALSI leverages the manufacturing DNA of the Japanese group to explore the "manufacturing site" deeply. Combining IoT technology, big data, AI, etc., with lean principles, it has developed the "Huipai Supply Chain Resource Planning Platform" and the "Jingzhi Lean Factory Cloud Platform," which are small, fast, light, and precise. These platforms aim to help more manufacturing customers achieve efficient on-site workshop management and embark on the path of digitalization and intelligent development.