Elite Team Series (Vol.1)：The Winning Secrets of the Wuhu Team

Thanks to the joint efforts of all members, the Churod Wuhu Team won the Group "Churod Award" in 2023. The team achieved outstanding results in key projects, manpower optimization projects, quality improvement initiatives and cost reduction programs.

In 2023, the per capita output value of the Manufacturing Department at the Wuhu Operations Center increased by 43% year-on-year;

 In 2023, scrap costs of the Manufacturing Department at the Wuhu Operations Center decreased by 57% year-on-year; 

In 2023, the defect rate from customer complaints at the Wuhu Operations Center dropped by 37% year-on-year; 

In 2023, the net profit of the Wuhu Operations Center rose by 185% year-on-year.

To uncover the "winning secrets" behind the remarkable achievements of the Wuhu team, we are honored to conduct an in-depth project interview with the Product Technology Manager and Manufacturing Manager, and share their insights with everyone.

PART 1   Rapid Delivery of Project XX

In 2023, the Wuhu Operations Team delivered the critical Class 1 project for European market expansion. The project officially kicked off on June 20, 2023, and achieved mass production delivery on August 31, 2023, within only 72 days! Such speed was unimaginable for Project XX, setting a new record for Product XX.

"Overcoming obstacles in this project has inspired the whole team and given a strong boost to the follow-up progress of our XX projects." The Product Technology Manager shared the numerous hurdles the team encountered during development. "We raced against time on product design, tolerance iteration and product performance simulation (theoretical data). During prototype production, we analyzed performance gaps between simulation and reality, and optimized product structure, drawings and dimensional precision of molds. Every step was closely linked and carefully planned. None of these could be achieved without joint efforts from all team members."

（Product Technology Manager：It took only 72 days from launch to delivery.）

It was no easy task to shorten the project timeline while ensuring quality compliance. To achieve this goal, the team innovated processes in the intermediate product testing stage. Three separate devices that previously measured individual data in three distinct procedures were consolidated into one single unit. This equipment measures by simulating product motion and generates force-distance curves to directly reflect product operating status and mechanical parameters for visual analysis and root cause identification. Supported by the newly built analysis and measurement platform, the team conducted in-depth logical analysis based on product structure and oscilloscope waveforms to quickly pinpoint root causes and accelerate design optimization.

At the project process stage, the team optimized six key processes one by one: brazing, in-process inspection, semi-finished product electrical test, laser welding, product performance test, and dynamic component baking / contact polishing / semi-finished mechanical aging / semi-finished product test. This greatly reduced costs and significantly improved product yield.

PART 2   Dual Strategies: Workforce Optimization & Quality Upgrade

Furthermore, the Wuhu Operations Team also achieved remarkable results in workforce optimization and quality improvement projects. In our interview with the Manufacturing Manager of the Wuhu Operations Team, he stated: "Quality engagement requires everyone’s participation. When following up on issues, our Wuhu team digs deep into root causes, delivers targeted solutions, pushes implementation vigorously, and rolls out improvements across all relevant areas. We review and discuss relevant records every week to ensure measures take effect." Meanwhile, he pointed out that the core of these two projects lies in "Equipment Empowers Quality". "Human performance cannot match machinery in stability and consistency. We invest in automated equipment to guarantee product quality. Part of the cost savings is fed back to employees, which better motivates the team and stabilizes product quality."

（Manufacturing Manager：Full-team participation to strictly control every process link）

Workforce optimization started with production lines. The introduction of CCD visual inspection in the winding workshop enabled one operator to manage three machines, while CCD deployment on the home appliance assembly line allowed one operator to run two machines. Meanwhile, one-on-one targeted training was provided for frontline staff to ensure consistent quality and delivery even amid surging workloads. In addition, automatic lines and mirror lines were introduced to the workshop, with upgrades implemented at key processes. "Previously these processes relied on manual operations. We replaced manual work with stamping machines to realize automated workflows. While cutting manpower, this also greatly reduced product defects caused by human operation."

（Pilot Rollout in the Winding Department & Home Appliance Assembly Line）

For quality control, the Wuhu Operations Team has developed its unique management model. Internally, the team appointed professional supervisors to strengthen training on core quality skills, enabling staff to fully integrate theoretical knowledge with practical capabilities.

Skill training comes with supporting assessments. The team continuously optimizes the frontline evaluation system to drive simultaneous improvement in delivery rate and quality. Besides, the Manufacturing Manager shared their practices: "We require supervisors to conduct on-site line walks every week. When defects are found, immediate on-site guidance and correction will be provided. We implement a mechanism to analyze defective products right upon detection. Once product issues occur, root causes and solutions must be identified promptly to prevent issue spread and resolve risks in advance. To raise everyone’s awareness of quality, we include quality KPIs in OKR assessments and adopt cross-role management, aligning all departments to boost learning and communication."

Externally, for quality management with suppliers and customers, the Wuhu team maintains rigorous standards and hands-on engagement. The Manufacturing Manager commented: "When quality issues arise at the supplier side, we require suppliers to come to our site for review. Likewise, if quality problems of our products occur at the customer site, our team supervisors, together with relevant staff, will rush to the scene immediately to conduct reviews and provide on-site solutions. This practice aims to strengthen every member’s sense of reverence for product quality."

Guided by the philosophy of "full participation" and "strict control" in quality management, the Wuhu team achieved this remarkable quality improvement.

PART 3 Targeted & Effective Cost Reduction Strategies

The Wuhu Operations Team has effectively cut labor costs and delivered cost reduction in other areas as well. In response to high industrial power consumption, dedicated staff are assigned to conduct circuit inspections to ensure equipment power is switched off promptly during idle periods and avoid unnecessary energy waste. Currently, the team targets to keep the monthly power consumption per KPC within a strict high-standard range. In addition, the team introduced a component lifecycle management strategy. With effective prediction, monitoring and maintenance plans, the service life of key components is greatly extended, lowering frequent repair costs caused by component failure. This proactive management strategy not only cuts maintenance expenses, but also ensures overall operational efficiency and stability of equipment. For components with abnormal consumption or high failure rates in daily operation, instead of simply replacing them, the team mobilized internal technical resources to attempt in-house repairs, further reducing spending on component maintenance and outsourced services. By now, you may have gained a clear understanding of what makes the Wuhu team outstanding.

Lastly, we would like to say: the company’s rapid development relies on every Churod employee working tirelessly at their posts. Dedicated to their roles and united by shared goals, they devote themselves wholeheartedly and break through one technical bottleneck after another. We believe more outstanding elite teams like this will emerge in the future. Please stay tuned!