(This case is anonymized; client name and specific location are withheld.)
Project Background
A manufacturer in South China built a new automated production line requiring PLC control cabinets, field distribution boxes, and junction boxes. Initially, multiple suppliers provided different equipment, but their communication interfaces and electrical standards were incompatible, leading to finger-pointing during commissioning and delays that threatened the line’s launch date.
Client Pain Points
- Incompatible communication interfaces across multiple suppliers
- Commissioning dragged on for two months without the line running
- Unclear responsibility when problems arose — suppliers blamed each other
- Line OEE (Overall Equipment Effectiveness) far below target
Xiaoyang Solution
We took over with a one-stop custom electrical integration service — unified design, unified manufacturing:
- Unified design: Our engineers drew the complete system schematics using one electrical standard and component brand from the main PLC cabinet down to field junction boxes
- Main PLC cabinet: Siemens S7-1200 master control with planned I/O and communication
- Field distribution boxes: Power distribution boxes rated per site conditions
- Junction boxes: Standardized field junction boxes for easy maintenance and spare parts
- Pre-commissioning at factory: Internal wiring, simulated signal testing, and program pre-tuning completed before delivery
Because all cabinets were designed and built by one manufacturer, on-site work only required connecting power and field signals, dramatically reducing commissioning effort.
Results
| Metric | Multi-Supplier Original | Xiaoyang One-Stop |
|---|---|---|
| Commissioning time | 2 months, not running | ~50% reduction (running in 3 weeks) |
| Responsibility | Multi-supplier finger-pointing | Single point (Xiaoyang) |
| Line OEE | Below target | Improved ~15% |
| Spare parts | Mixed brands | Unified brand and model |
The line launched on schedule. For subsequent expansions, the client reused Xiaoyang’s standard cabinet types, cutting delivery time to 7 days.
Explore Industrial Automation Solutions
If your production line faces multi-supplier interface chaos or long commissioning cycles, view our industrial automation control solution — Xiaoyang provides one-stop service from design to commissioning.
Related Products
- PLC Control Cabinet — custom line master control
- Custom Electrical Solutions — one-stop design and manufacturing