Zhoukou Automation Disc Forging Case, Henan

In the industrial heartland of Henan, Zhoukou has become a benchmark for automated forging solutions. Jianing Forging successfully addressed a critical production bottleneck for a local manufacturer, demonstrating how precision engineering and tailored automation can transform metal forming operations.

Case Overview

A medium-sized automotive parts supplier in Zhoukou faced escalating rejection rates in their manual disc forging line. The company required a reliable, high-consistency solution to meet growing OEM orders while reducing material waste and labor dependency.

Customer Challenges

The client struggled with three core issues: inconsistent dimensional accuracy across batches, frequent die wear leading to unscheduled downtime, and high scrap rates caused by manual handling errors. Their existing process also required skilled operators for each shift, creating staffing bottlenecks and quality variability.

Solution Provided

Jianing Forging deployed a fully automated disc forging cell integrating servo-driven presses, robotic part transfer, and real-time process monitoring. The solution reduced cycle time by 35% through optimized die temperature control and automated lubrication. A vision-guided loading system eliminated misalignment defects, achieving repeatable tolerances within ±0.1 mm. The closed-loop press force adjustment compensated for material variations, cutting scrap from 8% to under 1.5%.

By replacing manual inter-stage handling with a collaborative robot arm, the client eliminated operator safety risks and achieved consistent output across three shifts with minimal supervision. Post-installation data showed a 50% reduction in die maintenance frequency due to controlled forging parameters and predictive tool wear analytics.