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Henan Qianchao Intelligent Manufacturing Named an “Advanced-Level Smart Factory” in Henan Province
2026-07-24
Henan Qianchao Intelligent Manufacturing focuses on its two core areas—“casting and machining”—and has established a complete process chain covering smelting, molding, pouring, deburring, machining, inspection, and surface treatment. With smart manufacturing upgrades as its central focus, the company leverages next-generation information technologies such as the Industrial Internet, artificial intelligence, and big data to advance the intelligent transformation and digital upgrading of its production lines, thereby building an integrated digital operations management system.
The company has comprehensively deployed information systems such as SAP, MES, WMS, SRM, and PLM, integrating data channels across the entire value chain—including design, process engineering, production, warehousing, quality control, and supply chain—to achieve end-to-end digital collaboration. In the production workshops, 95.16% of the 59 sets of intelligent equipment are CNC-controlled; critical equipment is 100% networked; and over 200 sensors collect key process parameters—such as temperature, pressure, and tool life—in real time, with data refreshed once per second, providing a solid foundation for efficient and precise production scheduling.
In the product R&D phase, the company’s digital design system—based on CAD, CAE, and Magma—enables fully parametric product modeling and virtual process simulation. This has reduced the number of trial moldings for new products from 5 to 1, cut R&D trial-and-error costs by 60%, and compressed the brake disc structural optimization cycle from 45 days to 15 days.
In the manufacturing phase, the MES system works in close coordination with the WMS warehouse management system and RGV rail-guided vehicles. The three-dimensional sand core warehouse can automatically allocate storage locations and deliver materials with precision, reducing the delivery time per run from 25 minutes to 8 minutes, with a delivery on-time rate of 99%; The Marpos automatic inspection line performs 100% in-line full inspection, reducing the molten iron composition testing cycle from 15 minutes to 3 minutes, with the first-pass yield rate stabilizing at over 99.2%.
Through the construction of the smart factory, the company has achieved comprehensive optimization of its core operational metrics:
① Production efficiency increased by over 57%, operating costs decreased by over 34%, production plan fulfillment rate improved by 15%, and order delivery cycles were shortened by 58%.
② By leveraging the energy management system to optimize production scheduling during off-peak hours and simultaneously implementing energy-saving technical upgrades—such as waste heat recovery and variable-frequency drive retrofits for equipment—the company reduced energy consumption per unit of output by more than 22% and cut carbon emission intensity by 28%, successfully earning the designation of a National-Level Green Factory.
This recognition as a provincial-level advanced smart factory fully demonstrates Henan Qianchao Intelligent Manufacturing’s comprehensive capabilities in the field of smart manufacturing. The company will continue to enhance the flexibility of its production lines and their intelligent operational capabilities, striving to build a first-class, environmentally friendly, and digital high-end foundry demonstration facility in China, thereby continuously empowering the company’s high-quality development.
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