Stonbel Capacity Upgrade Document: Empowered by Intelligent Manufacturing, Consolidating Core Competitiveness in the Display Industry
Against the backdrop of rapid iteration in global display technologies and expanding market demand, Stonbel, an original manufacturer in the LED display sector, has launched a new round of capacity upgrades focused on high-end, intelligent and green development. This upgrade centers on three key areas: core technological breakthroughs, implementation of intelligent production lines, and optimized supply chain coordination. It comprehensively enhances production capacity, product precision and delivery efficiency, laying a solid production foundation for the company’s in-depth development in commercial display, government & enterprise, cultural tourism and other core segments, and driving the enterprise toward the high-end of the value chain.
I. Upgrade Background: Driven by Industry Transformation and Market Demand
The display industry is undergoing profound changes, shifting from traditional LED to Mini/Micro LED and from single-function displays to scenario-based applications. Demand for high-end products such as texture screens, COB small-pitch displays and thermal imaging equipment is growing rapidly, with higher customer requirements for delivery cycles, product consistency and customization capabilities. Meanwhile, intensifying industry competition has made production capacity and technological capabilities key indicators for building core competitiveness.
Based on its four core product lines (LED displays, LCD panels, thermal imaging equipment and LED texture screens), Stonbel addresses pain points of traditional production lines through this capacity upgrade, including bottlenecks in production capacity, long delivery cycles for high-end products and insufficient quality consistency. It aims to meet diversified global customer demands with larger capacity, higher precision and faster response.
II. Core Measures: Three-Dimensional Efforts to Build an Intelligent and Efficient Production System
(1) Intelligent Production Line Upgrade: Hardware Innovation to Unleash Production Potential
The upgrade focuses on equipment renewal in three core processes: LED packaging, module assembly and texture screen processing, introducing cutting-edge intelligent equipment to achieve simultaneous improvements in capacity and precision.
High-end packaging line renovationObsolete packaging equipment has been replaced with 10 new fully automatic Mini/Micro LED packaging lines equipped with high-precision mass transfer equipment (transfer accuracy ±1μm) and intelligent temperature-controlled reflow soldering systems, realizing automated control throughout the entire process from epitaxial wafer growth and chip manufacturing to packaging. After the upgrade, monthly production capacity reaches 75,000 pieces of 4-inch Mini LED chips and 3,000 pieces of Micro LED chips, with a stable mass transfer yield of 99.99%, breaking through bottlenecks in high-end packaging capacity.
Dedicated production line construction for texture screensIn response to the high camouflage precision and wide installation adaptability of texture screens, 6 customized production lines have been built with high-precision CNC processing equipment and intelligent lamination systems, enabling integrated production of customized ceramic texture mold processing and seamless screen lamination. The modular line design supports quick changeovers for different sizes and textures, with a monthly capacity of 1,800 ㎡ per line — a 60% efficiency improvement over traditional lines — fully meeting customization needs in commercial retail, real estate lighting, cultural tourism landscapes and other scenarios.
Implementation of automated assembly linesAGV robots and intelligent MES systems have been introduced to LED and LCD production lines, automating material handling, process assembly and quality inspection. RFID tags enable precise workpiece tracking, raising Overall Equipment Effectiveness (OEE) from 65% to 85% and shortening single-unit assembly cycles by 40%, greatly enhancing production stability.
(2) Digital Management Empowerment: Software Support for Lean Control
Alongside hardware upgrades, Stonbel has reconstructed its digital management system, breaking information silos across the entire chain from design, procurement, production and warehousing to logistics for refined whole-process control.
In-depth application of MES systemsA full Manufacturing Execution System (MES) has been deployed to collect real-time data on equipment status, process progress and quality, forming a digital twin of production. The APS advanced scheduling module automatically generates optimal production plans, reducing urgent order response time from 24 hours to 4 hours and increasing on-time order delivery rate to 99%. Full product lifecycle traceability is realized, with each finished product traceable to raw material batches, processing procedures and inspection data, improving quality traceability efficiency by 80%.
Seamless integration of ERP and MES systemsIntegration of Enterprise Resource Planning (ERP) and MES systems enables real-time synchronization of orders, inventory, procurement and financial data. Intelligent inventory management provides dynamic alerts and precise scheduling for raw materials and finished products, increasing warehouse space utilization by 40% and inventory turnover by 50%, resolving material overstocking and supply-demand mismatches in traditional production.
Establishment of a digital R&D platformAn upgraded 3D virtual design system integrates 3D modeling, simulation testing and process simulation, cutting new product R&D cycles from 30 days to 15 days and reducing R&D costs by 30%. A cloud-based technical database supports data sharing among R&D, production and sales teams for rapid response to customer customization needs.
(3) Supply Chain Coordination Optimization: Ecological Collaboration to Consolidate Production Capacity
Capacity upgrade is not only internal innovation but also a systematic effort of industrial chain collaboration. Focusing on strengthening, extending and stabilizing the supply chain, Stonbel has built a stable and efficient supply chain system to support full capacity release.
Independent R&D of core materialsThe company has established strategic partnerships with leading upstream suppliers for LED chips, packaging adhesives, texture panels and other core materials, while advancing independent R&D for key components. Currently, 15% of core materials are produced in-house, improving supply chain response speed by 35% and reducing raw material procurement costs by 12%, effectively mitigating supply disruption risks.
Digital supply chain collaborationA collaborative supply chain platform enables real-time sharing of orders, inventory and quality data with suppliers, driving synchronized upgrades in their production equipment and management systems. Through tiered supplier management, 20 core high-quality partners have been selected to establish mechanisms for rapid response, joint R&D and shared quality accountability, lifting overall supply chain efficiency by 45%.
Intelligent logistics system upgradeCooperating with third-party logistics providers, an intelligent warehousing and logistics center equipped with three-dimensional shelves and automatic sorting systems has been built to automate raw material storage and finished product delivery. Covering 10 core regions nationwide, the logistics network achieves 48-hour nationwide delivery — a 50% efficiency improvement over traditional logistics — providing efficient delivery services for customers.
III. Upgrade Results: Breakthroughs in Both Capacity and Value, Leading Industrial Upgrading
Upon completion of this capacity upgrade, Stonbel has achieved leaps in three core indicators: production capacity, product quality and efficiency, injecting strong momentum into high-quality development.
Substantial increase in production capacityOverall capacity has risen by 120%, with Mini LED capacity up 200% and texture screen capacity up 150%. Annual production capacity reaches 500,000 ㎡ of LED displays, 100,000 ㎡ of texture screens, 50,000 sets of thermal imaging equipment and 80,000 sets of conference all-in-one machines, fully meeting explosive global market demand.
Continuous product quality optimizationCore product defect rate has dropped from 0.3% to 0.05%. Key indicators of Mini/Micro LED products, including brightness and contrast, lead the industry, while texture screens feature greatly enhanced texture restoration and installation adaptability. The company has secured multiple benchmark projects in government & enterprise, cultural tourism and commercial retail, significantly strengthening market competitiveness.
Remarkable improvement in production efficiencyPer capita productivity has increased by 80%, and energy consumption per 10,000-yuan output value has decreased by 15%, achieving the triple goals of quality improvement, efficiency enhancement and cost reduction. Meanwhile, the digital management system has transformed corporate governance from experience-driven to data-driven, raising the level of refined production management to a new height.
