How to Improve the Production Efficiency of Double-Curved GRC Panels?

Improving the production efficiency of double-curved GRC panels is the key to reducing their high cost and broadening their scope of application. This requires systematic advancement across four dimensions: design optimization, mold innovation, process innovation, and lean management. Through digital technology and lean production management, Qinglong Group has significantly enhanced the production efficiency of double-curved GRC while ensuring the realization of complex forms.

Standardization and modularization at the design stage are the source of efficiency gains. When collaborating with architects, Qinglong's BIM team actively recommends breaking complex double-curved surfaces into reusable standardized modules wherever possible, provided the overall visual effect is satisfied. For example, through operations such as rotating and mirroring modules, rich visual effects can be created by combining a limited number of mold types. This "fewer specifications, more combinations" strategy can greatly reduce the number of molds and improve production line takt time.

Innovation in mold technology directly determines the production cycle. For double-curved GRC, traditional GRP molds are time-consuming and costly to fabricate. Qinglong promotes the use of "rapid mold systems", such as adjustable molds or master-mold replication technology based on 3D printing, which can shorten mold preparation time. Meanwhile, special surface treatment of molds improves demolding efficiency and mold service life, reducing cleaning and mold repair time during production.

Process flow optimization is crucial. Qinglong implements "cellular production" on its production lines, breaking down the double-curved panel production process into standardized workstations such as mold preparation, spraying/slurry flow, reinforcement layer laying, vacuum compaction, curing, and demolding, and reduces non-value-added time through tooling optimization. For example, robotic-assisted spraying is adopted to improve the uniformity of fiber distribution and production efficiency; vacuum bag pressing technology is introduced to replace part of the manual compaction, improving quality stability. In the curing stage, the curing cycle is shortened while ensuring quality through scientific design of the loading method and the temperature-humidity curves of the curing kilns.

Lean production management underpins system efficiency. Qinglong has implemented an ERP system for informatized management of the entire production process, enabling precise production scheduling, reducing mold changeover time, and optimizing material flow paths. Continuous employee training improves operators' proficiency and first-pass success rate. In the Guangxi New Media Center project, Qinglong, through the above comprehensive measures, still ensured on-time delivery of the project despite the extreme challenge of more than ten thousand square meters of double-curved panels with no two identical, demonstrating highly efficient production organization capabilities.