Project Background: The Challenge of Scalability and High Quality

For the flagship business IP phones of a world-leading telecommunications giant, the client demanded not only a high-gloss mirror aesthetic for the housing but also perfect quality consistency under high-volume production. To achieve a "Zero-Defect" mass production goal and minimize human assembly tolerances, Foreshot implemented a dedicated Fully Automated Integrated Production Line.

Manufacturing Challenges

• Quality Consistency in Mass Production: Manual assembly makes it difficult to ensure identical tactile feedback for keypads and uniform housing gaps across hundreds of thousands of units.
• Protection of Precision High-Gloss Housing: RHCM mirror-finish surfaces are extremely sensitive to scratches from manual handling. They require precise handling via automated robotic arms.
• Multi-Process Integration Pressure: Injection molding, double-shot inserting, AOI visual inspection, and final assembly must be completed within the same production cycle time.

Foreshot’s Automation Solution

Core Technology: Industry 4.0 Fully Automated Smart Production Line

We developed a customized multi-station automated production line for this project, integrating previously fragmented processes into a high-efficiency continuous flow.

1. Robotic-Assisted Precision Injection

By utilizing fully automated servo robotic arms paired with RHCM (Rapid Heat Cycle Molding) machines, the entire process—from mold opening and part extraction to trimming and automated de-static—is fully automated. This ensures that the high-gloss surfaces never come into contact with human hands, maintaining a 100% defect-free yield.

2. Double-Shot Keypad Injection & Automated Optical Inspection (AOI)

Immediately after the double-shot keypads are molded, they enter an AOI (Automated Optical Inspection) system. The system performs real-time evaluations of font integrity and backlight uniformity, automatically rejecting minute defects to ensure every assembled key meets high-precision standards.

3. Automated Assembly & Multi-Functional Testing Stations

We implemented automated screw-fastening robots and tactile feedback pressure sensors. These sensors record the physical data for every handset and keypad unit. The data is synchronized in real-time to a cloud-based Manufacturing Execution System (MES), achieving full production traceability throughout the entire process.

4. Automated Protective Packaging

Upon completion of the final assembly, automated lamination equipment applies protective films to the mirror-finish housing. The units then move directly into an automated packaging line, minimizing human contact-induced scratches to the greatest extent.

Project Results: The Value of Automation Excellence

• 99.9% AOI Inspection Accuracy
• 40% Reduction in Production Cycle Time
• 0% Human-Induced Scratch Attrition Rate
• 24/7 Stable and High-Efficiency Capacity