Introduction

The automotive industry demands precision, reliability, and high production volumes. This case study examines how a tier-2 automotive parts supplier in Thailand transformed their production capabilities by investing in a LAIFU 200T mechanical press machine.

Client Background

Company: Siam Auto Components Co., Ltd. (name changed for privacy)

Location: Chonburi, Thailand

Industry: Automotive parts manufacturing

Workforce: 350 employees

Products: Brake components, suspension parts, engine brackets

Challenge: Increasing production capacity while maintaining quality standards for major automotive OEMs

The Challenge

Siam Auto Components faced several critical challenges:

• Capacity constraints: Existing 150T press operating at 110% capacity
• Quality requirements: IATF 16949 certification demands consistent precision
• Delivery pressure: Just-in-time delivery to Toyota, Honda assembly plants
• Product complexity: New contracts requiring higher tonnage capabilities
• Downtime costs: Aging equipment causing 8-12 hours monthly downtime
• Skilled labor shortage: Need for easy-to-operate, reliable equipment
• Budget limitations: Need for cost-effective solution without compromising quality

The Solution

After evaluating multiple suppliers, Siam Auto Components selected LAIFU Press Machine:

• LAIFU MP-200 Mechanical Power Press
• Nominal pressure: 200 tons (2,000 kN)
• Slide stroke: 140mm
• Strokes per minute: 40-90 SPM
• Die height: 380mm
• Table size: 1,400 × 700mm
• Motor power: 22kW
• Weight: 18,500 kg

Key Features Selected:

• Pneumatic friction clutch and brake for safety
• PLC control system with touchscreen HMI
• Overload protection system
• Automatic lubrication system
• Die cushion system for deep drawing
• Safety light curtains and guards
• CE certification for international compliance

Implementation

Phase 1: Site Preparation (Week 1-2)

Factory modifications included:

• Reinforced foundation (25 tons static load capacity)
• Electrical supply upgrade (400V, 3-phase)
• Compressed air line installation (8 bar)
• Safety perimeter fencing

Phase 2: Installation and Commissioning (Week 3)

LAIFU technical team deployed to Thailand:

• Equipment unpacking and positioning
• Leveling and anchoring
• Electrical and pneumatic connections
• System calibration and testing
• Trial production runs

Phase 3: Training (Week 4)

Comprehensive training program for 18 operators and maintenance staff:

• Safe operation procedures (16 hours)
• Die setup and changeover procedures
• Daily inspection and maintenance
• Troubleshooting common issues
• Quality control procedures

Phase 4: Production Ramp-up (Week 5-6)

• Week 5: 50% capacity with existing dies
• Week 6: 100% capacity with optimized parameters

Results

After 10 months of operation, Siam Auto Components achieved outstanding results:

Production Performance

• 35% increase in overall production capacity
• 90 SPM average operating speed (vs. 60 SPM on old press)
• 99.2% uptime (only 6 hours unplanned downtime in 10 months)
• Zero quality rejects due to equipment issues

Quality Improvements

• ±0.02mm dimensional consistency (exceeds OEM requirements)
• Zero customer complaints related to press-produced parts
• Successful IATF 16949 surveillance audit
• Reduced scrap rate from 2.1% to 0.8%

Cost Savings

• $85,000 annual savings from eliminated outsourcing
• 40% reduction in maintenance costs vs. old equipment
• 25% lower energy consumption per part
• ROI achieved in 11 months

Operational Benefits

• Faster die changeover: 45 minutes vs. 90 minutes previously
• Improved worker safety: Modern safety systems, zero incidents
• Better workforce utilization: One operator can run 2 presses
• Enhanced reputation: Qualified for additional OEM contracts

Client Testimonial

“The LAIFU 200T press has been a game-changer for our business. We can now handle larger, more complex parts in-house instead of outsourcing. The precision is excellent, the reliability is outstanding, and our customers have noticed the quality improvement. LAIFU’s support team was professional throughout installation and training. We’re already planning to purchase another unit for our second facility.”

— Production Director, Siam Auto Components Co., Ltd.

Key Success Factors

• Right tonnage selection: 200T matched current and future requirements
• Quality manufacturer: LAIFU’s reputation for reliability proved accurate
• Comprehensive training: Well-trained operators maximize equipment potential
• Preventive maintenance: Following LAIFU maintenance schedule prevents issues
• Local support: LAIFU’s Southeast Asia service network provides rapid response

Technical Highlights

Features that made the difference:

• Rigid welded steel frame: Minimal deflection under load ensures precision
• Pneumatic clutch/brake: Fast response, reliable safety
• PLC control: Easy parameter adjustment and diagnostics
• Automatic lubrication: Consistent lubrication extends component life
• Overload protection: Prevents damage from misfeeds or double hits

Conclusion

This case study demonstrates how investing in quality press equipment can transform manufacturing capabilities. LAIFU Press Machine’s combination of reliable equipment, technical expertise, and regional support enabled Siam Auto Components to increase production capacity, improve quality, and win additional business from major automotive OEMs.

For automotive parts manufacturers in Southeast Asia, Middle East, South America, Africa, or Eastern Europe looking to expand their production capabilities, LAIFU Press Machine offers comprehensive solutions from 3T to 3200T with full technical support and after-sales service.

About LAIFU Press Machine

LAIFU Press Machine is a leading manufacturer and exporter of mechanical and hydraulic press machines, serving customers worldwide with equipment ranging from 3T to 3200T. Contact us today for a consultation on your specific press requirements.