In 2013, Longcheng Precision Forging set an ambitious goal: to increase its share of the global market to 35% and aim for one out of every three cars worldwide to use the company’s forged claws. Chairman Zhuang Longxing expressed confidence in the company's future, emphasizing that with steady order inflow and efficient automated production capabilities, reaching sales over 1 billion yuan was achievable.
At the start of 2010, as orders from the U.S. and Europe surged, Longcheng faced a challenge in meeting its production demands. The factory needed to process the plane, outer circle, and inner hole of generator claw poles continuously for 24 hours without interruption, aiming for an annual output of 10 million units. However, at that time, only a few production lines were available, making it nearly impossible to meet such high volume. The traditional assembly line method caused inefficiencies—when equipment stopped, roughing and finishing could not proceed simultaneously, leading to coordination issues and production delays. Additionally, rising labor costs in China further constrained expansion efforts. Ensuring timely delivery while maintaining product quality became a pressing issue for the management team.
To address these challenges, Longcheng’s engineers explored various solutions. After careful evaluation, they decided to invest in new automated production equipment and implement an intelligent production management system. EMAG quickly emerged as the top choice due to its reputation for high-quality machines and successful automation cases. “We’ve known about EMAG’s vertical lathes for a long time,†said Xu Jin, Deputy General Manager of Production. “As a manufacturer producing 40 million claw poles annually, automation is essential. Their success stories convinced us, and we are confident in their tailored VL 3 vertical lathe solution.â€
After implementing the automated system, Longcheng saw a 50% increase in production efficiency, reducing the machining cycle from three shifts to just one. Previously, three workers were needed for roughing, but now one operator can handle both roughing and finishing on the same line, achieving 900 units per shift. This significant improvement allowed the company to scale up operations efficiently.
Longcheng produces over 40 different types of products, requiring two production line changes every seven days. The VL 3 vertical lathe, equipped with a robot for loading and unloading, offers short stroke and compact design, enabling fast clamping and tact times. This flexibility ensures smooth processing even with frequent batch size changes and part modifications. With EMAG’s automation solutions, Longcheng achieved a 34% time saving.
Moreover, given the high volume of output, speed and reduced manpower were crucial. EMAG selected two VL 3 machines with a reversing robot as a production unit, allowing one operator to manage four machines efficiently. To ensure consistent quality, EMAG provided specialized chucks and cutting tools, enabling 24/7 continuous machining.
By the end of 2013, Longcheng planned to expand further by investing in 28 VL 3 production lines. Automation also improved logistics and space utilization, as the new equipment covered only 70% of the original footprint, reducing operating costs. The integrated loading and unloading systems allowed operators to remove finished parts and insert new blanks without interrupting the CNC conveyor belt, significantly boosting efficiency.
EMAG was more than just a supplier; it became a trusted partner. The company collaborated closely with Longcheng to align with future product development and technical requirements, ensuring safety, quality, and operational efficiency. EMAG also offered comprehensive training programs for employees, covering equipment operation, maintenance, and performance. These sessions, lasting 3–5 days, helped staff become more proficient in managing the production line.
Chairman Zhuang Longxing emphasized the strategic value of the partnership with EMAG. “Our goal is to become the leader in China’s precision forging industry and the world’s largest supplier of precision forged claws for automotive engines. EMAG’s experience in European and American markets will support our future technological advancements and international marketing strategies.â€
With continued investment in automation and strong collaboration with EMAG, Longcheng Precision Forging was well-positioned to achieve its ambitious targets and solidify its presence in the global automotive supply chain.
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