1. Requirement Confirmation
Requirement confirmation serves as the foundation. According to industry project principles, thorough initial requirement confirmation minimizes losses from late-stage changes. Key aspects include: Requirement dimensions—product quality standards, equipment production efficiency targets, and the operating environment;
Material properties—dimensions, unit weight, form (solid/flexible/liquid), and special characteristics (anti-static, high-temperature resistance, food-grade, corrosion resistance; specifications must be precise regarding diameter and weight, rather than just stating “small parts”); Production requirements—cycle time (throughput), conveying precision, and needs for diverting, merging, buffering, lifting, or transfer stations; Site constraints—factory dimensions, equipment accessibility (entry to the site and freight elevators), layout configuration, color scheme, and specified brands (for motors, guide rails, cylinders, etc.); and Acceptance criteria—cycle time and yield rate. The Requirement Confirmation Document is more valuable than elaborate proposal drawings; the clearer the requirements are defined, the fewer detours will be encountered.
2.
Proposal and Quotation
Proposal design and quotation.
Based on standard industry workflows, the proposal phase involves the following steps: Process Planning—engineers design the equipment’s complete operational sequence and plan the mechanical structure, drive mechanisms, and positioning/inspection schemes; 3D Modeling—generating 3D renderings and machine layout drawings to visualize the arrangement of fixtures, robots, and inspection units; Electrical Control Planning—selecting models for PLCs, servos, sensors, and vision systems, drafting electrical schematics, and planning communication interfaces; Proposal Review—evaluating feasibility, costs, production efficiency, and the structural viability of individual components; Quotation—itemizing costs for machined parts, standard components, electrical parts, and labor (commissioning), then calculating a detailed quote; Client Interaction/Requirement Verification—aligning the proposal precisely with the intended use case (omissions in communication during the drawing stage often lead to costly on-site changes later; the proposal acts as a translation of requirements, and the project proceeds only after approval).
III.
Contracts and Agreements
Contracts and technical agreements.
Following industry customization workflows, three elements are finalized during the contract phase: Technical Agreement—documenting technical parameters, acceptance criteria, and delivery milestones for the custom equipment (specific details are crucial for non-standard products); Customization Contract—specifying delivery timelines, after-sales terms, and payment methods; Payment Schedule—phasing payments into advance, progress, acceptance, and warranty retention stages; Change Management—establishing a formal process for changes made after the design is frozen, including limits on the number of revisions and associated costs; Milestone Plan—mapping out the sequence: proposal confirmation → 3D design review → 3D design freeze → 2D drafting → BOM release → procurement → assembly → commissioning → internal acceptance → shipment (with specific deliverables for each milestone); Pre-shipment Acceptance—for critical projects, stipulating the client’s right to conduct a pre-shipment inspection at the factory, with shipment permitted only after successful acceptance (clear contractual terms ensure the successful execution of non-standard projects).
IV.
Design and Procurement
Design, procurement, and manufacturing/machining.
In accordance with industry workflows, the design and procurement process proceeds as follows: Mechanical Design—involves 3D modeling (frame structure, fixture design), 2D drafting, and BOM (Bill of Materials) compilation, ensuring accuracy in dimensions, tolerances, and materials for every part; the structural design undergoes multi-dimensional review before the drawings and BOM are finalized to generate the procurement list. Electrical Design—includes PLC programming, touchscreen interface design, circuit routing planning, and sensor layout. Simulation—complex non-standard equipment undergoes simulation testing to identify structural interference issues in advance. Procurement—acquisition of standard components such as motors, cylinders, sensors, servo modules, and industrial control elements. Machining—the factory’s machine shop fabricates parts such as frames, jigs, and tooling. Quality Inspection—all components undergo inspection before warehousing; the “freezing” of drawings signals the completion of design, while the release of the BOM marks the start of procurement.
V.
Assembly and Acceptance
Assembly, debugging, acceptance, and delivery.
The assembly and debugging process follows these steps: Assembly—technicians perform mechanical assembly, electrical wiring, and pneumatic routing based on assembly drawings to complete the machine build; this stage adheres to industrial production standards and strictly controls assembly precision to minimize future malfunctions. Debugging—comprehensive debugging is conducted after assembly; Design of Experiments (DOE) is used to measure the impact of variables—such as servo speed, pressure, and light intensity—on the yield rate (e.g., identifying the optimal combination of 80 mm/s speed, 10 N pressure, and 3000 lux illumination). Trial Run—quality checks and trial runs verify cycle time and yield rates. Internal Acceptance—the manufacturer conducts internal acceptance testing before shipment. On-site Installation—equipment is delivered to the site for installation, debugging, and final acceptance/handover. Documentation Archiving—includes operation manuals, circuit diagrams, lists of wear parts, and maintenance support; assembly precision determines the failure rate, while debugging parameters determine the yield rate—both are critical metrics for acceptance.
Conclusion
What is the process for customizing a non-standard assembly line? The sequence is: Requirements → Proposal → Contract → Design → Procurement → Assembly → Commissioning → Acceptance → After-sales service. Each step is interconnected and indispensable.
Requirements: Quality, efficiency, environmental factors, material properties (dimensions, unit weight, form, special characteristics), production requirements (cycle time, precision, diversion, buffering), site constraints (factory layout, freight elevators, branding/color schemes), and acceptance criteria. Proposal: Operational workflow, 3D layout, electrical scheme (PLC, servo, vision system models), review (feasibility, cost, efficiency, structure), and itemized quotation. Contract: Formalizing technical parameters, acceptance criteria, and delivery milestones; defining lead times, after-sales terms, payment methods, and pre-acceptance procedures. Design & Procurement: 3D design review and freeze → 2D drawing generation → BOM release → procurement of standard parts → machining of custom parts → quality inspection and warehousing. Assembly & Commissioning: Mechanical assembly, electrical wiring, and pneumatic routing; DOE (Design of Experiments) to optimize parameters; trial runs and quality checks; internal acceptance → shipment → on-site installation → final acceptance and handover → documentation archiving and after-sales maintenance.
Industry practice dictates that non-standard customization is a form of project management rather than a simple equipment purchase—every milestone involves specific deliverables, and every stage includes review points.
Time spent clarifying requirements early on saves money by preventing rework later.
