Client Background
The client is a global leader in electronics and mechanical industry one-stop infrastructure services, delivering over 17.8 million orders annually to 8.2+ million customers across 180 countries and regions.
The company has been listed on the "Hurun Global Unicorn Index" for 5 consecutive years, operating five modern digital manufacturing bases covering the full service chain 鈥?electronic component procurement, PCB manufacturing, SMT assembly, and mechanical processing.
Project Background: Breaking Through Manual Efficiency Bottlenecks
The client's Zhuhai warehouse faced two critical pain points:
- Inefficient manual measurement: Manual volume and weight measurement was slow and inaccurate, impacting downstream outbound and billing processes
- High sorting error rate: Traditional manual sorting led to frequent errors, affecting customer delivery experience 鈥?especially in high-SKU, high-volume scenarios
The company decided to deploy automated sorting equipment to fundamentally solve these operational issues.
Solution: Sorting Wall + Conveyor System Combination
As a professional sorting equipment manufacturer, Bdaitec tailored a dual-line inbound + outbound automation solution for the Zhuhai facility:
| Process | Equipment | Sorting Logic |
|---|---|---|
| Inbound Sorting | 15m Automated Sorting Wall | Sort by aisle/location |
| Outbound Sorting | Roller DWS Conveyor Sorting System | Sort by shipping channel |
Product Highlights
- Sorting Wall: 15m length, widened bays with enlarged chutes; bay sizes configured to actual requirements; tested sorting efficiency of 1,400 items/hour
- Outbound Sorting Line: Dual-level design 鈥?upper level for empty bin return, lower level for package outbound; automated empty bin recycling saves space and labor
Solution Highlights
- Sorting wall automatically reads barcodes 鈥?operators simply place items on the induction station, shuttles sort to target bays, dramatically reducing human error
- Overflow detection alerts when items accumulate beyond set threshold, preventing missed sorts
- Outbound DWS system handles weighing and dimensioning, data auto-uploads to ERP for improved accuracy
- Inbound + outbound dual-line integration achieves full warehouse automation loop
On-Site Footage
Below is real footage of the sorting wall equipment deployed at the client's Zhuhai facility:
Implementation: 30-Day Seamless Cutover
The entire project 鈥?equipment installation, commissioning, and training 鈥?was completed in just 30 days. Bdaitec's team overcame two key challenges:
馃敡 Challenge 1: Site Constraints
The installation site was on the 2nd floor with a narrow entrance, making it impossible to bring complete equipment through. Solution: disassemble equipment and hoist to 2nd floor, then reassemble on-site for complete delivery.
馃彮 Challenge 2: Zero-Downtime Implementation
The warehouse had to maintain normal operations throughout installation. Solution: phased approach 鈥?daytime operations continued as usual, nighttime installation and commissioning, achieving seamless cutover.
With Bdaitec's professional project management, the client completed automation upgrades with zero business disruption.
Results: Drastically Reduced Error Rates
Since going live, the Zhuhai facility has seen significant improvements:
| Metric | Improvement |
|---|---|
| Sorting Error Rate | Drastically reduced, errors nearly eliminated |
| Process Efficiency | Optimized warehouse flow, sorting efficiency significantly improved |
| Labor Dependency | Reduced reliance on experienced workers, new hires onboard quickly |
| Data Accuracy | Automatic volume/weight data collection, accuracy significantly improved |
Client Feedback: "Very satisfied with the volume and weight accuracy. The sorting wall's overall automation level is high, passed testing with satisfaction."
Summary
This project demonstrates how a large electronics manufacturer can solve operational pain points with smart warehouse equipment. As a professional sorting equipment manufacturer, Bdaitec's sorting wall + conveyor sorting system combination was delivered seamlessly within 30 days, helping the client achieve:
- 鉁?Drastically reduced sorting errors
- 鉁?Automated warehouse workflow upgrade
- 鉁?Lower labor dependency
- 鉁?Significantly improved data accuracy
Bdaitec is committed to delivering efficient, reliable warehouse automation solutions across industries 鈥?from electronics manufacturing and e-commerce logistics to third-party warehousing 鈥?with end-to-end support from requirements analysis through go-live.