1. Customer Overview Card
Insta360, founded in 2015, primarily focuses on the research, development, production, and sales of consumer-grade handheld smart imaging devices including panoramic cameras and action cameras. Since becoming the largest brand in global panoramic camera shipments in 2018, Insta360 has developed rapidly, achieving approximately 50% market share in the panoramic camera market in 2022. Insta360 has also formed strategic collaborations with brands like Leica, Google, Facebook, Twitter (now X), and multimedia editing software service provider Adobe. In March 2018, Insta360 officially entered the global Apple retail stores and has since launched several products including the X series, ONE R series, GO series, and Flow, remaining the only panoramic imaging brand introduced in the Apple stores.
Main products: Currently, Insta360 offers five models of handheld smart cameras, among which three consumer-grade product series are the GO series, X series, and ONE R series, plus two professional products: Pro 2 and Titan.
Staff scale: 1000+
Production output value: Expected to reach over 4 billion RMB in 2023.
Industry position: In 2023, Insta360's market share in the global panoramic camera market is 67%, ranking first, and it also maintains a strong position in the action camera market, second only to GoPro.
Application industry: Consumer electronics / 3C smart hardware.
Main market: Over 70% overseas (Europe and America), domestic.
Downstream customers: End users.
Production process: Assembly.
Insta360 Product Line
2. Project Background Introduction
Insta360 features small iterative and fast R&D characteristics, requiring software and hardware collaborative development. It has now formed a diverse technical system, including core technologies such as panoramic imagery, capturing and stitching, anti-shake technology, AI image processing, computational photography, and modular waterproof cameras. The new product development process must meet standards at every stage from validation, testing to mass production; any substandard part may require rework, leading to a plethora of job types and complex processes.
As the shipment volume continues to grow, the requirements for product traceability become increasingly stringent. To support the strategic goal of achieving 10 billion in three years, the company currently utilizes information tools including ERP, PLM, WMS, Lark, etc., making the construction of MES systems an urgent task in factory digitalization. Insta360's Marketing Director Yuan Yue believes that the core criterion for selecting digital tools is "results-oriented". Essentially, it is crucial to delve into business process bottlenecks and identify what problems the tools can solve.
3. Business Process
Business Process
3.1 Host Business Process
Host Business Process
3.2 Set Business Process
Set Business Process
3.3 Accessory Business
Accessory Business Process
4. Project Blueprint (Goals)
Establish fool-proof management for accessory product placement to prevent misassembly and omission of sets flowing into the market, while archiving SN information within the system.
Overall lifecycle control of host products, implementing comprehensive management over man, machine, material, methods, and environment.
Management of employee skills and working hours.
Achieve production cost control.
Interconnect with production testing software to realize mutual access and traceability of quality master data and assembly master data.
MES Introduction Business Goals
MES Introduction System Integration Goals
After Solution Application
5. Specific Solution Process
5.1 Host Production Solutions
5.1.1 Workstation On-Site Management
Solution Introduction: Employees can quickly jump to the current work order and report work by scanning the SN code or batch code. The system sets various fool-proof scenarios, such as intercepting non-conforming products and avoiding duplicate scanning, ensuring production accuracy. Additionally, for complex electronic industry requirements, the solution supports SN replacement, SN comparison, automatic SN printing, and more, enhancing the flexibility and efficiency of production operations. Simultaneously, the direct recognition of external SN barcodes also provides convenience for clients managing the MES system, eliminating the need to complete raw material SN/batch purchasing inbound through the operating system and allowing for seamless integration of the entire traceability process on the workstation page.
Before Application (BEFORE)
Unable to quickly and accurately locate the current work order and production tasks of employees, requiring significant time and effort in manual recording and searching for information, which lowered operational efficiency.
The manual assembly process is prone to errors, such as misreporting work orders, duplicate reports, and incorrect use of assembly materials, leading to inaccurate production data that affects FPY and OQC production quality indicators.
Lack of systematic fool-proof mechanisms impairs capacity scaling.
After Application (AFTER)
Employees quickly jump to the current work order and report work by scanning the SN code, making the operation more convenient and efficient.
The system sets multiple fool-proof scenarios, including non-conforming products cannot be scanned past stations, SN/batch already scanned and reported at the current workstation cannot be scanned again, finished product SN not flowing to the current production position cannot be scanned, finished products of different work orders and lines cannot be produced together, and raw materials not assigned to the current work order cannot consume materials, ensuring the accuracy of operations.
Production continuity improves, with UPH capacity steadily increasing.
Scene Diagram
Single SN Production Reporting
Fool-proof Assembly Reporting for Single SN Production
Product Data Package Link: A | Workstation On-Site Management
5.1.2 Offline Repair
Solution Introduction: The offline repair solution can timely intercept, mark, and isolate non-conforming products to avoid them mixing into the normal production process. The system records non-conforming product information through special labels and stores them in designated areas to ensure they are not misused. At the same time, it tracks and analyzes return information in real-time, optimizing production processes to improve efficiency and quality. Using mobile terminals to record return information and uploading it in real-time to the quality management system facilitates subsequent tracking and analysis. When operating the return line, it records the information of the repaired materials and allows customization of return processing steps as needed to achieve more precise production quality management.
Before Application (BEFORE)
Insta360's recording and tracking of non-conforming products’ repair processes are inaccurate, resulting in unclear repair processes and difficulty in quickly identifying and resolving issues.
There is a tendency for information about non-conforming products to be lost or inaccurately recorded.
Manual recording and handling of non-conforming product return information is cumbersome and time-consuming, leading to low repair efficiency that impacts production progress and product quality.
After Application (AFTER)
The system accurately tracks and records each non-conforming product's repair process, including repair time, reason, operation, etc., making the repair process transparent and controllable.
The solution simplifies the repair process, achieving real-time recording and tracing of information and shortening the handling cycle of non-conforming products.
Scene Diagram
Product Data Package Link: A | Offline Repair
5.1.3 Packing Management
Solution Introduction: The packing management solution provides flexible packing methods and fool-proof rules. Production supervisors can print box codes in advance, and on-site workers can pack by scanning, with the system automatically recording and binding product information to ensure accurate packing. Fool-proof rules can be set based on materials, work orders, and workstations to avoid packing errors, and tracing functions can efficiently locate and resolve issues.
Before Application (BEFORE)
In the past, manual packing at Insta360 could sometimes result in mixed or wrong packing, leading to packing categories and quantities not meeting requirements.
The previous paper management was unable to accurately record packing information, making it difficult to trace the packing situation of products and affecting the efficiency and accuracy of product traceability.
After Application (AFTER)
Quantity fool-proof: The system sets a rule that requires scanning the correct quantity for packing to succeed, ensuring that packing quantities meet requirements and avoiding quantity errors.
Category fool-proof: The system sets rules based on product categories to ensure that the packed product categories meet requirements, avoiding mixing or wrong packing.
Tracing function: The system records packing information, achieving real-time recording and tracing of packing data, facilitating subsequent product tracing and management, thus improving tracing efficiency.
Interface Diagram
Single SN Scanning for Packing
Full Box Trigger to Read Full Box Weight Data
Product Data Package Link: A | Packing Management
5.1.4 Serial Number (SN) Management
Solution Introduction: The SN Serial Number solution aims to achieve systematic management and real-time tracing of Insta360's product serial numbers. Its characteristics include supporting diverse configurations, having fool-proof functionality and uniqueness verification, and enabling efficient and flexible SN full-process input scenarios. By real-time dynamically tracing the latest dynamics and location of each SN, this solution can achieve end-to-end recording of all inventory, production, inspection, etc., thus ensuring the accuracy and traceability of product serial numbers.
Before Application (BEFORE)
Lacking a unique serial number identifier, Insta360 could not accurately trace products' production, flow, and usage data, making tracing a tedious process requiring extensive paper documentation.
Without serial number identifiers, Insta360 finds it challenging to accurately identify and differentiate different products and semi-finished products, leading to assembly errors.
Insta360's product information records are incomplete, preventing a comprehensive understanding of product lifecycle and historical records.
After Application (AFTER)
Insta360 generates a unique serial number identifier for each product based on SN mapping rules, facilitating tracing and recognition while ensuring product uniqueness and traceability.
Records conditions of production, flow, and usage of products, achieving binding of finished product SNs with semi-finished SNs for fool-proof assembly calibration.
The SN serial number can trace every product's complete lifecycle information.
Interface Diagram
Single SN Scanning for Production
Single SN Scanning Production Fool-proof
Single SN Scanning Weight + Packing
Single SN Scanning for Weight
Product Data Package Link: S | Serial Number (SN) Management
5.1.5 After-sales Repair (RC)
Solution Introduction: The after-sales repair management solution achieves systematic management across the full process, including online recording of after-sales repair data, real-time tracking of after-sales progress, and independent management of after-sales work orders and work reporting pages to ensure orderly execution of after-sales processes. Additionally, the system records the entire disassembly and assembly process, ensuring the reliability and traceability of after-sales services.
Before Application (BEFORE)
The after-sales repair process records at Insta360 are incomplete, making it difficult to accurately understand the details and progress of each repair.
Simultaneously, Insta360 requires substantial manpower for manual recording and communication, leading to inefficiencies and a high error rate.
In the past, there were frequent occurrences of after-sales materials being mixed with regular materials, leading to disorder in work orders and confusion in processes that affected the quality of after-sales service.
Insta360 finds it challenging to trace after-sales repair operations and has poor traceability.
After Application (AFTER)
Insta360 utilizes the new hub cloud MES integrated with multiple systems, achieving full digital management across the process, recording after-sales repair data to ensure information transparency.
With online management, Insta360 can track after-sales progress in real-time, optimizing the follow-up of after-sales service.
Insta360 can establish independent after-sales work orders, set independent processes for after-sales materials, and prevent confusion and disorder in work orders and processes.
Recording the entire disassembly process enhances traceability in Insta360's after-sales repair process.
Product Data Package Link: S+ | After-sales Repair Management
5.1.6 End-to-End Traceability
Solution Introduction: The SN full process traceability solution covers the entire production process from procurement to inbound to finished product sales. With traceability supporting end-to-end tracing of each manufacturing step and related information of a single product, real-time management enables viewing and locating SN information, while post-process management supports both reverse and forward traceability, helping to quickly locate and manage issues in the production process.
Before Application (BEFORE)
Previously, Insta360 could not accurately record the production process and historical records of each product, which limited effective tracing of the product's origin, manufacturing process, and flow status.
On the production floor, it was difficult to obtain accurate information regarding a product's production status, quality condition, and lifecycle, affecting production decisions and quality control.
When quality issues or recalls arose in products, it was challenging to quickly locate the range and causes of affected products, leading to disputes and complications.
After Application (AFTER)
Insta360 records each product's operations from procurement inbound to finished product sales through the system, including production, inspection, packing, etc., enabling comprehensive traceability.
The production floor provides real-time and accurate operation information, helping production supervisors gain insights into each product's production status and quality condition.
In the event of quality issues or recall incidents, the system can quickly locate the range and causes of affected products, thereby mitigating the impact and loss.
Interface Diagram
SN End-to-End Traceability
Product Data Package Link: A | End-to-End Traceability
5.2 Gift Box Packaging Production Solutions
5.2.1 Workstation On-Site Management
Solution Introduction: Employees can quickly jump to the current work order and report work by scanning the SN code or batch code. The system sets multiple fool-proof scenarios, such as intercepting non-conforming products and avoiding duplicate scanning, ensuring production accuracy. Additionally, for complex electronic industry demands, the solution supports SN replacement, SN comparison, automatic SN printing, etc., enhancing flexibility and efficiency in production operations. The direct recognition of external SN barcodes also provides convenience for clients managing the MES system, eliminating the need to complete raw material SN/batch purchasing inbound through the operating system, allowing for seamless integration of the overall traceability process on the workstation page.
Before Application (BEFORE)
Unable to quickly and accurately locate the current work order and production tasks of employees, requiring significant time and effort in manual recording and searching for information, which reduced operational efficiency.
The manual assembly process is prone to errors, such as misreporting work orders, duplicate reports, and incorrect use of assembly materials, leading to inaccurate production data that affects FPY and OQC production quality indicators.
Lack of systematic fool-proof mechanisms affects capacity scaling.
After Application (AFTER)
Employees quickly jump to the current work order and report work by scanning the SN code, making the operation more convenient and efficient.
The system sets multiple fool-proof scenarios, including non-conforming products cannot be scanned past stations, SN/batch already scanned and reported at the current workstation cannot be scanned again, finished product SN not flowing to the current production position cannot be scanned, finished products of different work orders and lines cannot be produced together, and raw materials not assigned to the current work order cannot consume materials, ensuring the accuracy of operations.
Production continuity improves, with UPH capacity steadily increasing.
Scene Diagram
Single SN Production Reporting
Single SN Production Assembly Reporting Fool-proof
Product Data Package Link: A | Workstation On-Site Management
5.2.2 CCD Photo Verification Integration
Solution Introduction: The new hub cloud CCD vision capture device integration is based on the CCD vision capture device, which records test results via interfaces and intermediate forms. During the user's production reporting or inspection reporting phase, the control machine or phone synchronously displays the corresponding CCD captured data as a reference to guide and analyze production/inspection.
Before Application (BEFORE)
Previously, Insta360 equipment captured test images that existed solely in testing equipment, requiring manual entry into the system.
With numerous testing images on the production line, manual synchronization became cumbersome, affecting production cadence and delaying production.
Timely data entry for test results led to unreferenced reporting data, failing to meet expected production outcomes and causing quality issues.
After Application (AFTER)
Once the configuration of CCD integration parameters is complete, the device simply conducts the normal test and uploads the result data, making it convenient and efficient, with zero errors.
CCD testing images synchronize for review on the reporting page and production record, allowing production and management personnel to make swift production decisions.
Reporting records are tied to CCD testing results. By tracing reports through SN, CCD images can be reviewed, allowing for problem location.
Scene Diagram
MES and CCD Image Device Connection
Automatically collect weight data based on results to report qualifying or non-qualifying products.
Product Data Package Link: A | CCD Photo Verification Integration
5.2.3 Packing Management
Solution Introduction: The packing management solution provides flexible packing methods and fool-proof rules. Production supervisors can print box codes in advance, and on-site workers can pack by scanning, with the system automatically recording and binding product information to ensure accurate packing. Fool-proof rules can be set based on materials, work orders, and workstations to avoid packing errors, and tracing functions can efficiently locate and resolve issues.
Before Application (BEFORE)
In the past, manual packing at Insta360 sometimes resulted in mixed or wrong packing, leading to packing categories and quantities not meeting requirements.
The previous paper management was unable to accurately record packing information, making it difficult to trace the packing situation of products and affecting the efficiency and accuracy of product traceability.
After Application (AFTER)
Quantity fool-proof: The system establishes rules requiring scanning of sufficient quantities for packing to succeed, ensuring packing quantities meet requirements and avoiding errors.
Category fool-proof: The system sets rules based on product categories to ensure that the packed product categories meet requirements, avoiding mixing or wrong packing.
Tracing function: The system records packing information, achieving real-time recording and tracing of packing data, facilitating subsequent product tracing and management, thus improving tracing efficiency.
Interface Diagram
Product Data Package Link: A | Packing Management
5.2.4 Weight Verification
Solution Introduction: The new hub cloud's weight verification connects to weighing equipment, automatically collecting weight data and visually validating the results. By using a combination of software and hardware, users can efficiently collect weight data during the production/packing process, improving work efficiency in single and whole box weighing while ensuring effective fool-proof management throughout the process.
Before Application (BEFORE)
Manual recording of weight data is prone to missing or erroneous entries, resulting in incomplete and untraceable data during the production process, complicating quality management and issue tracking.
Lacking real-time monitoring and validation tools for weight data leaves the ability to detect and correct abnormalities during weighing processes diminished, reducing quality control.
After Application (AFTER)
Integration between the MES and electronic scales achieves automatic collection and validation of weight data, providing complete data traceability and ensuring data integrity and traceability during the production process, facilitating quality management and issue analysis.
Real-time monitoring of the weighing process enables the timely detection and correction of weighing anomalies, improving the real-time nature and accuracy of quality management.
Scene Diagram
Weight Verification
Product Data Package Link: B | Weight Verification
5.2.5 Serial Number (SN) Management
Solution Introduction: The SN serial number solution aims to achieve systematic management and real-time tracing of Insta360's product serial numbers. Its characteristics include supporting flexible and diverse configurations, possessing error prevention fool-proof functionality and uniqueness verification, and enabling efficient and flexible SN full-process input scenarios. By dynamically tracing the latest dynamics and location of each SN in real-time, this solution can achieve comprehensive records of all inventory, production, inspection, etc., thus ensuring the accuracy and traceability of product serial numbers.
Before Application (BEFORE)
Without a unique serial number identifier, Insta360 could not accurately trace the production, flow, and usage of products, requiring extensive paper documentation that is time-consuming and cumbersome.
Without serial number identifiers, Insta360 faced challenges in accurately identifying and differentiating different products and semi-finished products, leading to assembly errors.
Insta360's product information records remained incomplete, hindering accurate understanding of product lifecycle and historical records.
After Application (AFTER)
Insta360 generates a unique serial number identifier for each product based on SN mapping rules, facilitating tracing and recognition while ensuring product uniqueness and traceability.
Records conditions of production, flow, and usage of products, achieving binding of finished product SNs with semi-finished SNs for fool-proof assembly calibration.
The SN serial number allows full tracing of each product's lifecycle information.
Interface Diagram
Product Data Package Link: S | Serial Number (SN) Management
5.2.5 After-sales Repair (RC) (Pending April Update)
Solution Introduction: The after-sales repair management solution achieves systematic full-process management, including online recording of after-sales repair data, real-time tracking of after-sales progress, and independent management of after-sales work orders and reporting pages to ensure orderly execution of after-sales processes. Moreover, the system records the entire disassembly and assembly process, ensuring reliability and traceability of after-sales services.
Before Application (BEFORE)
The after-sales repair process records at Insta360 are incomplete and fail to provide accurate details and progress of each repair.
Simultaneously, Insta360 requires substantial manpower for manual recording and communication, leading to inefficiencies and a heightened likelihood of errors.
Previously, there were frequent occurrences of after-sales materials being mixed with regular materials, leading to disorder in work orders and confusion in processes affecting the quality of after-sales service.
Insta360 struggles with the traceability of after-sales repair operations, which suffer from poor accountability.
After Application (AFTER)
Insta360 utilizes the new hub cloud MES integrated with multiple systems to facilitate full digital management across the process, recording after-sales repair data for transparency.
With online management, Insta360 can monitor after-sales progress in real-time, enhancing the efficiency and timeliness of service follow-up.
Insta360 can set independent after-sales work orders with unique processes for after-sales materials, preventing confusion in work orders and processes.
By documenting the entire disassembly and assembly process, Insta360 improves the traceability of after-sales repair operations.
Product Data Package Link: S+ | After-sales Repair Management
5.3 Rework Order Management
Solution Introduction: The new hub cloud's rework order management provides independent management of the rework process, assigning unique processing steps and work orders for rework materials to ensure the orderly conduct of rework processes. It features a specially customized reporting page supporting recording specific data related to material disassembly, assembly, and repairs. Furthermore, the disassembly material tracking function leverages historical records and planned materials to prevent wrong disassembly and incorrect assembly, thus ensuring accuracy and reliability throughout the rework process.
Before Application (BEFORE)
Insta360 previously lacked clear rework order management guidelines, causing disorganized rework processes and difficulties tracking material disassembly, assembly, and repairs.
Incomplete records of rework processes made accurately tracing the source and handling of issues problematic.
Operators often executed rework without guidance, which led to mistakes like disassembly errors and mistakes in assembly, ultimately impacting product quality and production efficiency.
After Application (AFTER)
Establishing independent rework orders allows assignment of unique processing steps and work orders to each rework material, ensuring organized rework processes.
Specialized reporting pages enable recording of operations during the rework, such as material disassembly, assembly, and repairs, facilitating accurate data documentation and traceability.
Utilizing disassembly and assembly material lists enables fool-proof validation during the disassembly and assembly process to avert errors, thereby enhancing the accuracy and reliability of the rework processes.
Product Data Package Link: B | Rework Order Management
5.3.7 Full Process Traceability
Solution Introduction: The SN full process traceability solution covers the entire production process, from procurement inbound to finished product sales, supporting end-to-end tracing of each manufacturing step along with related information. During the process, management allows real-time visibility and tracking of SN information, and management thereafter supports reverse and forward traceability, aiming to quickly identify and manage issues within the production workflow.
Before Application (BEFORE)
Insta360 previously faced challenges in accurately recording each product's production process and historical records, which hampered effective tracing of products' origins, manufacturing processes, and flow statuses.
On the production floor, difficulties arose in obtaining accurate insights on product production status, quality conditions, and lifecycles, affecting production decisions and quality controls.
In cases of product quality issues or recalls, it became challenging to locate affected product ranges and reasons quickly, leading to disputes over responsibility.
After Application (AFTER)
Insta360's system documents every product from procurement to finished product sales, including production, inspection, packing, etc., thus enabling comprehensive traceability.
The production floor provides real-time, precise operation information, enabling production supervisors to clearly comprehend the production status and quality of each product.
In case of product quality issues or recall events, the system can rapidly pinpoint the affected product ranges and reasons, mitigating the impact and loss.
Interface Diagram
Scene Video
6. Application Value
The Insta360 Innovation Factory has achieved remarkable results in digital transformation, with a comprehensive summary of these achievements presented below:
Implementation of fool-proof and error-prevention management for products: A highly efficient error-prevention system has been successfully implemented, ensuring correct assembly of accessories and preventing errors or omissions in gift box sets from flowing into the market. Additionally, detailed record-keeping of product serial number (SN) information provides reliable data support for product quality tracing.
Lifecycle control of host products: Comprehensive control has been established across all phases of host products, encompassing personnel, machines, materials, methods, and environments. This lifecycle management model enhances product reliability and market competitiveness.
Management of employee skills and working hours: Effective management of employee skills has been enacted, optimizing working hour allocation to ensure production efficiency and employee satisfaction.
Control of production costs: Monitoring and controlling production costs more accurately allows for real-time data analysis and cost forecasting, facilitating timely adjustments to production strategies and optimizing resource allocation, thereby lowering overall costs.
Synchronized interaction between production and testing software: Seamless integration between production systems and testing software allows quality master data and assembly master data to communicate easily, accelerating problem response times.
In summary, the digital transformation outcomes of the Insta360 Innovation Factory are significant, not only improving production efficiency and product quality but also optimizing cost control and employee management, laying a solid foundation for supporting the strategic goal of achieving 10 billion in three years.
1. Customer Overview Card
Insta360, founded in 2015, primarily focuses on the research, development, production, and sales of consumer-grade handheld smart imaging devices including panoramic cameras and action cameras. Since becoming the largest brand in global panoramic camera shipments in 2018, Insta360 has developed rapidly, achieving approximately 50% market share in the panoramic camera market in 2022. Insta360 has also formed strategic collaborations with brands like Leica, Google, Facebook, Twitter (now X), and multimedia editing software service provider Adobe. In March 2018, Insta360 officially entered the global Apple retail stores and has since launched several products including the X series, ONE R series, GO series, and Flow, remaining the only panoramic imaging brand introduced in the Apple stores.
Main products: Currently, Insta360 offers five models of handheld smart cameras, among which three consumer-grade product series are the GO series, X series, and ONE R series, plus two professional products: Pro 2 and Titan.
Staff scale: 1000+
Production output value: Expected to reach over 4 billion RMB in 2023.
Industry position: In 2023, Insta360's market share in the global panoramic camera market is 67%, ranking first, and it also maintains a strong position in the action camera market, second only to GoPro.
Application industry: Consumer electronics / 3C smart hardware.
Main market: Over 70% overseas (Europe and America), domestic.
Downstream customers: End users.
Production process: Assembly.
Insta360 Product Line
2. Project Background Introduction
Insta360 features small iterative and fast R&D characteristics, requiring software and hardware collaborative development. It has now formed a diverse technical system, including core technologies such as panoramic imagery, capturing and stitching, anti-shake technology, AI image processing, computational photography, and modular waterproof cameras. The new product development process must meet standards at every stage from validation, testing to mass production; any substandard part may require rework, leading to a plethora of job types and complex processes.
As the shipment volume continues to grow, the requirements for product traceability become increasingly stringent. To support the strategic goal of achieving 10 billion in three years, the company currently utilizes information tools including ERP, PLM, WMS, Lark, etc., making the construction of MES systems an urgent task in factory digitalization. Insta360's Marketing Director Yuan Yue believes that the core criterion for selecting digital tools is "results-oriented". Essentially, it is crucial to delve into business process bottlenecks and identify what problems the tools can solve.
3. Business Process
Business Process
3.1 Host Business Process
Host Business Process
3.2 Set Business Process
Set Business Process
3.3 Accessory Business
Accessory Business Process
4. Project Blueprint (Goals)
Establish fool-proof management for accessory product placement to prevent misassembly and omission of sets flowing into the market, while archiving SN information within the system.
Overall lifecycle control of host products, implementing comprehensive management over man, machine, material, methods, and environment.
Management of employee skills and working hours.
Achieve production cost control.
Interconnect with production testing software to realize mutual access and traceability of quality master data and assembly master data.
MES Introduction Business Goals
MES Introduction System Integration Goals
After Solution Application
5. Specific Solution Process
5.1 Host Production Solutions
5.1.1 Workstation On-Site Management
Solution Introduction: Employees can quickly jump to the current work order and report work by scanning the SN code or batch code. The system sets various fool-proof scenarios, such as intercepting non-conforming products and avoiding duplicate scanning, ensuring production accuracy. Additionally, for complex electronic industry requirements, the solution supports SN replacement, SN comparison, automatic SN printing, and more, enhancing the flexibility and efficiency of production operations. Simultaneously, the direct recognition of external SN barcodes also provides convenience for clients managing the MES system, eliminating the need to complete raw material SN/batch purchasing inbound through the operating system and allowing for seamless integration of the entire traceability process on the workstation page.
Before Application (BEFORE)
Unable to quickly and accurately locate the current work order and production tasks of employees, requiring significant time and effort in manual recording and searching for information, which lowered operational efficiency.
The manual assembly process is prone to errors, such as misreporting work orders, duplicate reports, and incorrect use of assembly materials, leading to inaccurate production data that affects FPY and OQC production quality indicators.
Lack of systematic fool-proof mechanisms impairs capacity scaling.
After Application (AFTER)
Employees quickly jump to the current work order and report work by scanning the SN code, making the operation more convenient and efficient.
The system sets multiple fool-proof scenarios, including non-conforming products cannot be scanned past stations, SN/batch already scanned and reported at the current workstation cannot be scanned again, finished product SN not flowing to the current production position cannot be scanned, finished products of different work orders and lines cannot be produced together, and raw materials not assigned to the current work order cannot consume materials, ensuring the accuracy of operations.
Production continuity improves, with UPH capacity steadily increasing.
Scene Diagram
Single SN Production Reporting
Fool-proof Assembly Reporting for Single SN Production
Product Data Package Link: A | Workstation On-Site Management
5.1.2 Offline Repair
Solution Introduction: The offline repair solution can timely intercept, mark, and isolate non-conforming products to avoid them mixing into the normal production process. The system records non-conforming product information through special labels and stores them in designated areas to ensure they are not misused. At the same time, it tracks and analyzes return information in real-time, optimizing production processes to improve efficiency and quality. Using mobile terminals to record return information and uploading it in real-time to the quality management system facilitates subsequent tracking and analysis. When operating the return line, it records the information of the repaired materials and allows customization of return processing steps as needed to achieve more precise production quality management.
Before Application (BEFORE)
Insta360's recording and tracking of non-conforming products’ repair processes are inaccurate, resulting in unclear repair processes and difficulty in quickly identifying and resolving issues.
There is a tendency for information about non-conforming products to be lost or inaccurately recorded.
Manual recording and handling of non-conforming product return information is cumbersome and time-consuming, leading to low repair efficiency that impacts production progress and product quality.
After Application (AFTER)
The system accurately tracks and records each non-conforming product's repair process, including repair time, reason, operation, etc., making the repair process transparent and controllable.
The solution simplifies the repair process, achieving real-time recording and tracing of information and shortening the handling cycle of non-conforming products.
Scene Diagram
Product Data Package Link: A | Offline Repair
5.1.3 Packing Management
Solution Introduction: The packing management solution provides flexible packing methods and fool-proof rules. Production supervisors can print box codes in advance, and on-site workers can pack by scanning, with the system automatically recording and binding product information to ensure accurate packing. Fool-proof rules can be set based on materials, work orders, and workstations to avoid packing errors, and tracing functions can efficiently locate and resolve issues.
Before Application (BEFORE)
In the past, manual packing at Insta360 could sometimes result in mixed or wrong packing, leading to packing categories and quantities not meeting requirements.
The previous paper management was unable to accurately record packing information, making it difficult to trace the packing situation of products and affecting the efficiency and accuracy of product traceability.
After Application (AFTER)
Quantity fool-proof: The system sets a rule that requires scanning the correct quantity for packing to succeed, ensuring that packing quantities meet requirements and avoiding quantity errors.
Category fool-proof: The system sets rules based on product categories to ensure that the packed product categories meet requirements, avoiding mixing or wrong packing.
Tracing function: The system records packing information, achieving real-time recording and tracing of packing data, facilitating subsequent product tracing and management, thus improving tracing efficiency.
Interface Diagram
Single SN Scanning for Packing
Full Box Trigger to Read Full Box Weight Data
Product Data Package Link: A | Packing Management
5.1.4 Serial Number (SN) Management
Solution Introduction: The SN Serial Number solution aims to achieve systematic management and real-time tracing of Insta360's product serial numbers. Its characteristics include supporting diverse configurations, having fool-proof functionality and uniqueness verification, and enabling efficient and flexible SN full-process input scenarios. By real-time dynamically tracing the latest dynamics and location of each SN, this solution can achieve end-to-end recording of all inventory, production, inspection, etc., thus ensuring the accuracy and traceability of product serial numbers.
Before Application (BEFORE)
Lacking a unique serial number identifier, Insta360 could not accurately trace products' production, flow, and usage data, making tracing a tedious process requiring extensive paper documentation.
Without serial number identifiers, Insta360 finds it challenging to accurately identify and differentiate different products and semi-finished products, leading to assembly errors.
Insta360's product information records are incomplete, preventing a comprehensive understanding of product lifecycle and historical records.
After Application (AFTER)
Insta360 generates a unique serial number identifier for each product based on SN mapping rules, facilitating tracing and recognition while ensuring product uniqueness and traceability.
Records conditions of production, flow, and usage of products, achieving binding of finished product SNs with semi-finished SNs for fool-proof assembly calibration.
The SN serial number can trace every product's complete lifecycle information.
Interface Diagram
Single SN Scanning for Production
Single SN Scanning Production Fool-proof
Single SN Scanning Weight + Packing
Single SN Scanning for Weight
Product Data Package Link: S | Serial Number (SN) Management
5.1.5 After-sales Repair (RC)
Solution Introduction: The after-sales repair management solution achieves systematic management across the full process, including online recording of after-sales repair data, real-time tracking of after-sales progress, and independent management of after-sales work orders and work reporting pages to ensure orderly execution of after-sales processes. Additionally, the system records the entire disassembly and assembly process, ensuring the reliability and traceability of after-sales services.
Before Application (BEFORE)
The after-sales repair process records at Insta360 are incomplete, making it difficult to accurately understand the details and progress of each repair.
Simultaneously, Insta360 requires substantial manpower for manual recording and communication, leading to inefficiencies and a high error rate.
In the past, there were frequent occurrences of after-sales materials being mixed with regular materials, leading to disorder in work orders and confusion in processes that affected the quality of after-sales service.
Insta360 finds it challenging to trace after-sales repair operations and has poor traceability.
After Application (AFTER)
Insta360 utilizes the new hub cloud MES integrated with multiple systems, achieving full digital management across the process, recording after-sales repair data to ensure information transparency.
With online management, Insta360 can track after-sales progress in real-time, optimizing the follow-up of after-sales service.
Insta360 can establish independent after-sales work orders, set independent processes for after-sales materials, and prevent confusion and disorder in work orders and processes.
Recording the entire disassembly process enhances traceability in Insta360's after-sales repair process.
Product Data Package Link: S+ | After-sales Repair Management
5.1.6 End-to-End Traceability
Solution Introduction: The SN full process traceability solution covers the entire production process from procurement to inbound to finished product sales. With traceability supporting end-to-end tracing of each manufacturing step and related information of a single product, real-time management enables viewing and locating SN information, while post-process management supports both reverse and forward traceability, helping to quickly locate and manage issues in the production process.
Before Application (BEFORE)
Previously, Insta360 could not accurately record the production process and historical records of each product, which limited effective tracing of the product's origin, manufacturing process, and flow status.
On the production floor, it was difficult to obtain accurate information regarding a product's production status, quality condition, and lifecycle, affecting production decisions and quality control.
When quality issues or recalls arose in products, it was challenging to quickly locate the range and causes of affected products, leading to disputes and complications.
After Application (AFTER)
Insta360 records each product's operations from procurement inbound to finished product sales through the system, including production, inspection, packing, etc., enabling comprehensive traceability.
The production floor provides real-time and accurate operation information, helping production supervisors gain insights into each product's production status and quality condition.
In the event of quality issues or recall incidents, the system can quickly locate the range and causes of affected products, thereby mitigating the impact and loss.
Interface Diagram
SN End-to-End Traceability
Product Data Package Link: A | End-to-End Traceability
5.2 Gift Box Packaging Production Solutions
5.2.1 Workstation On-Site Management
Solution Introduction: Employees can quickly jump to the current work order and report work by scanning the SN code or batch code. The system sets multiple fool-proof scenarios, such as intercepting non-conforming products and avoiding duplicate scanning, ensuring production accuracy. Additionally, for complex electronic industry demands, the solution supports SN replacement, SN comparison, automatic SN printing, etc., enhancing flexibility and efficiency in production operations. The direct recognition of external SN barcodes also provides convenience for clients managing the MES system, eliminating the need to complete raw material SN/batch purchasing inbound through the operating system, allowing for seamless integration of the overall traceability process on the workstation page.
Before Application (BEFORE)
Unable to quickly and accurately locate the current work order and production tasks of employees, requiring significant time and effort in manual recording and searching for information, which reduced operational efficiency.
The manual assembly process is prone to errors, such as misreporting work orders, duplicate reports, and incorrect use of assembly materials, leading to inaccurate production data that affects FPY and OQC production quality indicators.
Lack of systematic fool-proof mechanisms affects capacity scaling.
After Application (AFTER)
Employees quickly jump to the current work order and report work by scanning the SN code, making the operation more convenient and efficient.
The system sets multiple fool-proof scenarios, including non-conforming products cannot be scanned past stations, SN/batch already scanned and reported at the current workstation cannot be scanned again, finished product SN not flowing to the current production position cannot be scanned, finished products of different work orders and lines cannot be produced together, and raw materials not assigned to the current work order cannot consume materials, ensuring the accuracy of operations.
Production continuity improves, with UPH capacity steadily increasing.
Scene Diagram
Single SN Production Reporting
Single SN Production Assembly Reporting Fool-proof
Product Data Package Link: A | Workstation On-Site Management
5.2.2 CCD Photo Verification Integration
Solution Introduction: The new hub cloud CCD vision capture device integration is based on the CCD vision capture device, which records test results via interfaces and intermediate forms. During the user's production reporting or inspection reporting phase, the control machine or phone synchronously displays the corresponding CCD captured data as a reference to guide and analyze production/inspection.
Before Application (BEFORE)
Previously, Insta360 equipment captured test images that existed solely in testing equipment, requiring manual entry into the system.
With numerous testing images on the production line, manual synchronization became cumbersome, affecting production cadence and delaying production.
Timely data entry for test results led to unreferenced reporting data, failing to meet expected production outcomes and causing quality issues.
After Application (AFTER)
Once the configuration of CCD integration parameters is complete, the device simply conducts the normal test and uploads the result data, making it convenient and efficient, with zero errors.
CCD testing images synchronize for review on the reporting page and production record, allowing production and management personnel to make swift production decisions.
Reporting records are tied to CCD testing results. By tracing reports through SN, CCD images can be reviewed, allowing for problem location.
Scene Diagram
MES and CCD Image Device Connection
Automatically collect weight data based on results to report qualifying or non-qualifying products.
Product Data Package Link: A | CCD Photo Verification Integration
5.2.3 Packing Management
Solution Introduction: The packing management solution provides flexible packing methods and fool-proof rules. Production supervisors can print box codes in advance, and on-site workers can pack by scanning, with the system automatically recording and binding product information to ensure accurate packing. Fool-proof rules can be set based on materials, work orders, and workstations to avoid packing errors, and tracing functions can efficiently locate and resolve issues.
Before Application (BEFORE)
In the past, manual packing at Insta360 sometimes resulted in mixed or wrong packing, leading to packing categories and quantities not meeting requirements.
The previous paper management was unable to accurately record packing information, making it difficult to trace the packing situation of products and affecting the efficiency and accuracy of product traceability.
After Application (AFTER)
Quantity fool-proof: The system establishes rules requiring scanning of sufficient quantities for packing to succeed, ensuring packing quantities meet requirements and avoiding errors.
Category fool-proof: The system sets rules based on product categories to ensure that the packed product categories meet requirements, avoiding mixing or wrong packing.
Tracing function: The system records packing information, achieving real-time recording and tracing of packing data, facilitating subsequent product tracing and management, thus improving tracing efficiency.
Interface Diagram
Product Data Package Link: A | Packing Management
5.2.4 Weight Verification
Solution Introduction: The new hub cloud's weight verification connects to weighing equipment, automatically collecting weight data and visually validating the results. By using a combination of software and hardware, users can efficiently collect weight data during the production/packing process, improving work efficiency in single and whole box weighing while ensuring effective fool-proof management throughout the process.
Before Application (BEFORE)
Manual recording of weight data is prone to missing or erroneous entries, resulting in incomplete and untraceable data during the production process, complicating quality management and issue tracking.
Lacking real-time monitoring and validation tools for weight data leaves the ability to detect and correct abnormalities during weighing processes diminished, reducing quality control.
After Application (AFTER)
Integration between the MES and electronic scales achieves automatic collection and validation of weight data, providing complete data traceability and ensuring data integrity and traceability during the production process, facilitating quality management and issue analysis.
Real-time monitoring of the weighing process enables the timely detection and correction of weighing anomalies, improving the real-time nature and accuracy of quality management.
Scene Diagram
Weight Verification
Product Data Package Link: B | Weight Verification
5.2.5 Serial Number (SN) Management
Solution Introduction: The SN serial number solution aims to achieve systematic management and real-time tracing of Insta360's product serial numbers. Its characteristics include supporting flexible and diverse configurations, possessing error prevention fool-proof functionality and uniqueness verification, and enabling efficient and flexible SN full-process input scenarios. By dynamically tracing the latest dynamics and location of each SN in real-time, this solution can achieve comprehensive records of all inventory, production, inspection, etc., thus ensuring the accuracy and traceability of product serial numbers.
Before Application (BEFORE)
Without a unique serial number identifier, Insta360 could not accurately trace the production, flow, and usage of products, requiring extensive paper documentation that is time-consuming and cumbersome.
Without serial number identifiers, Insta360 faced challenges in accurately identifying and differentiating different products and semi-finished products, leading to assembly errors.
Insta360's product information records remained incomplete, hindering accurate understanding of product lifecycle and historical records.
After Application (AFTER)
Insta360 generates a unique serial number identifier for each product based on SN mapping rules, facilitating tracing and recognition while ensuring product uniqueness and traceability.
Records conditions of production, flow, and usage of products, achieving binding of finished product SNs with semi-finished SNs for fool-proof assembly calibration.
The SN serial number allows full tracing of each product's lifecycle information.
Interface Diagram
Product Data Package Link: S | Serial Number (SN) Management
5.2.5 After-sales Repair (RC) (Pending April Update)
Solution Introduction: The after-sales repair management solution achieves systematic full-process management, including online recording of after-sales repair data, real-time tracking of after-sales progress, and independent management of after-sales work orders and reporting pages to ensure orderly execution of after-sales processes. Moreover, the system records the entire disassembly and assembly process, ensuring reliability and traceability of after-sales services.
Before Application (BEFORE)
The after-sales repair process records at Insta360 are incomplete and fail to provide accurate details and progress of each repair.
Simultaneously, Insta360 requires substantial manpower for manual recording and communication, leading to inefficiencies and a heightened likelihood of errors.
Previously, there were frequent occurrences of after-sales materials being mixed with regular materials, leading to disorder in work orders and confusion in processes affecting the quality of after-sales service.
Insta360 struggles with the traceability of after-sales repair operations, which suffer from poor accountability.
After Application (AFTER)
Insta360 utilizes the new hub cloud MES integrated with multiple systems to facilitate full digital management across the process, recording after-sales repair data for transparency.
With online management, Insta360 can monitor after-sales progress in real-time, enhancing the efficiency and timeliness of service follow-up.
Insta360 can set independent after-sales work orders with unique processes for after-sales materials, preventing confusion in work orders and processes.
By documenting the entire disassembly and assembly process, Insta360 improves the traceability of after-sales repair operations.
Product Data Package Link: S+ | After-sales Repair Management
5.3 Rework Order Management
Solution Introduction: The new hub cloud's rework order management provides independent management of the rework process, assigning unique processing steps and work orders for rework materials to ensure the orderly conduct of rework processes. It features a specially customized reporting page supporting recording specific data related to material disassembly, assembly, and repairs. Furthermore, the disassembly material tracking function leverages historical records and planned materials to prevent wrong disassembly and incorrect assembly, thus ensuring accuracy and reliability throughout the rework process.
Before Application (BEFORE)
Insta360 previously lacked clear rework order management guidelines, causing disorganized rework processes and difficulties tracking material disassembly, assembly, and repairs.
Incomplete records of rework processes made accurately tracing the source and handling of issues problematic.
Operators often executed rework without guidance, which led to mistakes like disassembly errors and mistakes in assembly, ultimately impacting product quality and production efficiency.
After Application (AFTER)
Establishing independent rework orders allows assignment of unique processing steps and work orders to each rework material, ensuring organized rework processes.
Specialized reporting pages enable recording of operations during the rework, such as material disassembly, assembly, and repairs, facilitating accurate data documentation and traceability.
Utilizing disassembly and assembly material lists enables fool-proof validation during the disassembly and assembly process to avert errors, thereby enhancing the accuracy and reliability of the rework processes.
Product Data Package Link: B | Rework Order Management
5.3.7 Full Process Traceability
Solution Introduction: The SN full process traceability solution covers the entire production process, from procurement inbound to finished product sales, supporting end-to-end tracing of each manufacturing step along with related information. During the process, management allows real-time visibility and tracking of SN information, and management thereafter supports reverse and forward traceability, aiming to quickly identify and manage issues within the production workflow.
Before Application (BEFORE)
Insta360 previously faced challenges in accurately recording each product's production process and historical records, which hampered effective tracing of products' origins, manufacturing processes, and flow statuses.
On the production floor, difficulties arose in obtaining accurate insights on product production status, quality conditions, and lifecycles, affecting production decisions and quality controls.
In cases of product quality issues or recalls, it became challenging to locate affected product ranges and reasons quickly, leading to disputes over responsibility.
After Application (AFTER)
Insta360's system documents every product from procurement to finished product sales, including production, inspection, packing, etc., thus enabling comprehensive traceability.
The production floor provides real-time, precise operation information, enabling production supervisors to clearly comprehend the production status and quality of each product.
In case of product quality issues or recall events, the system can rapidly pinpoint the affected product ranges and reasons, mitigating the impact and loss.
Interface Diagram
Scene Video
6. Application Value
The Insta360 Innovation Factory has achieved remarkable results in digital transformation, with a comprehensive summary of these achievements presented below:
Implementation of fool-proof and error-prevention management for products: A highly efficient error-prevention system has been successfully implemented, ensuring correct assembly of accessories and preventing errors or omissions in gift box sets from flowing into the market. Additionally, detailed record-keeping of product serial number (SN) information provides reliable data support for product quality tracing.
Lifecycle control of host products: Comprehensive control has been established across all phases of host products, encompassing personnel, machines, materials, methods, and environments. This lifecycle management model enhances product reliability and market competitiveness.
Management of employee skills and working hours: Effective management of employee skills has been enacted, optimizing working hour allocation to ensure production efficiency and employee satisfaction.
Control of production costs: Monitoring and controlling production costs more accurately allows for real-time data analysis and cost forecasting, facilitating timely adjustments to production strategies and optimizing resource allocation, thereby lowering overall costs.
Synchronized interaction between production and testing software: Seamless integration between production systems and testing software allows quality master data and assembly master data to communicate easily, accelerating problem response times.
In summary, the digital transformation outcomes of the Insta360 Innovation Factory are significant, not only improving production efficiency and product quality but also optimizing cost control and employee management, laying a solid foundation for supporting the strategic goal of achieving 10 billion in three years.
1. Customer Overview Card
Insta360, founded in 2015, primarily focuses on the research, development, production, and sales of consumer-grade handheld smart imaging devices including panoramic cameras and action cameras. Since becoming the largest brand in global panoramic camera shipments in 2018, Insta360 has developed rapidly, achieving approximately 50% market share in the panoramic camera market in 2022. Insta360 has also formed strategic collaborations with brands like Leica, Google, Facebook, Twitter (now X), and multimedia editing software service provider Adobe. In March 2018, Insta360 officially entered the global Apple retail stores and has since launched several products including the X series, ONE R series, GO series, and Flow, remaining the only panoramic imaging brand introduced in the Apple stores.
Main products: Currently, Insta360 offers five models of handheld smart cameras, among which three consumer-grade product series are the GO series, X series, and ONE R series, plus two professional products: Pro 2 and Titan.
Staff scale: 1000+
Production output value: Expected to reach over 4 billion RMB in 2023.
Industry position: In 2023, Insta360's market share in the global panoramic camera market is 67%, ranking first, and it also maintains a strong position in the action camera market, second only to GoPro.
Application industry: Consumer electronics / 3C smart hardware.
Main market: Over 70% overseas (Europe and America), domestic.
Downstream customers: End users.
Production process: Assembly.
Insta360 Product Line
2. Project Background Introduction
Insta360 features small iterative and fast R&D characteristics, requiring software and hardware collaborative development. It has now formed a diverse technical system, including core technologies such as panoramic imagery, capturing and stitching, anti-shake technology, AI image processing, computational photography, and modular waterproof cameras. The new product development process must meet standards at every stage from validation, testing to mass production; any substandard part may require rework, leading to a plethora of job types and complex processes.
As the shipment volume continues to grow, the requirements for product traceability become increasingly stringent. To support the strategic goal of achieving 10 billion in three years, the company currently utilizes information tools including ERP, PLM, WMS, Lark, etc., making the construction of MES systems an urgent task in factory digitalization. Insta360's Marketing Director Yuan Yue believes that the core criterion for selecting digital tools is "results-oriented". Essentially, it is crucial to delve into business process bottlenecks and identify what problems the tools can solve.
3. Business Process
Business Process
3.1 Host Business Process
Host Business Process
3.2 Set Business Process
Set Business Process
3.3 Accessory Business
Accessory Business Process
4. Project Blueprint (Goals)
Establish fool-proof management for accessory product placement to prevent misassembly and omission of sets flowing into the market, while archiving SN information within the system.
Overall lifecycle control of host products, implementing comprehensive management over man, machine, material, methods, and environment.
Management of employee skills and working hours.
Achieve production cost control.
Interconnect with production testing software to realize mutual access and traceability of quality master data and assembly master data.
MES Introduction Business Goals
MES Introduction System Integration Goals
After Solution Application
5. Specific Solution Process
5.1 Host Production Solutions
5.1.1 Workstation On-Site Management
Solution Introduction: Employees can quickly jump to the current work order and report work by scanning the SN code or batch code. The system sets various fool-proof scenarios, such as intercepting non-conforming products and avoiding duplicate scanning, ensuring production accuracy. Additionally, for complex electronic industry requirements, the solution supports SN replacement, SN comparison, automatic SN printing, and more, enhancing the flexibility and efficiency of production operations. Simultaneously, the direct recognition of external SN barcodes also provides convenience for clients managing the MES system, eliminating the need to complete raw material SN/batch purchasing inbound through the operating system and allowing for seamless integration of the entire traceability process on the workstation page.
Before Application (BEFORE)
Unable to quickly and accurately locate the current work order and production tasks of employees, requiring significant time and effort in manual recording and searching for information, which lowered operational efficiency.
The manual assembly process is prone to errors, such as misreporting work orders, duplicate reports, and incorrect use of assembly materials, leading to inaccurate production data that affects FPY and OQC production quality indicators.
Lack of systematic fool-proof mechanisms impairs capacity scaling.
After Application (AFTER)
Employees quickly jump to the current work order and report work by scanning the SN code, making the operation more convenient and efficient.
The system sets multiple fool-proof scenarios, including non-conforming products cannot be scanned past stations, SN/batch already scanned and reported at the current workstation cannot be scanned again, finished product SN not flowing to the current production position cannot be scanned, finished products of different work orders and lines cannot be produced together, and raw materials not assigned to the current work order cannot consume materials, ensuring the accuracy of operations.
Production continuity improves, with UPH capacity steadily increasing.
Scene Diagram
Single SN Production Reporting
Fool-proof Assembly Reporting for Single SN Production
Product Data Package Link: A | Workstation On-Site Management
5.1.2 Offline Repair
Solution Introduction: The offline repair solution can timely intercept, mark, and isolate non-conforming products to avoid them mixing into the normal production process. The system records non-conforming product information through special labels and stores them in designated areas to ensure they are not misused. At the same time, it tracks and analyzes return information in real-time, optimizing production processes to improve efficiency and quality. Using mobile terminals to record return information and uploading it in real-time to the quality management system facilitates subsequent tracking and analysis. When operating the return line, it records the information of the repaired materials and allows customization of return processing steps as needed to achieve more precise production quality management.
Before Application (BEFORE)
Insta360's recording and tracking of non-conforming products’ repair processes are inaccurate, resulting in unclear repair processes and difficulty in quickly identifying and resolving issues.
There is a tendency for information about non-conforming products to be lost or inaccurately recorded.
Manual recording and handling of non-conforming product return information is cumbersome and time-consuming, leading to low repair efficiency that impacts production progress and product quality.
After Application (AFTER)
The system accurately tracks and records each non-conforming product's repair process, including repair time, reason, operation, etc., making the repair process transparent and controllable.
The solution simplifies the repair process, achieving real-time recording and tracing of information and shortening the handling cycle of non-conforming products.
Scene Diagram
Product Data Package Link: A | Offline Repair
5.1.3 Packing Management
Solution Introduction: The packing management solution provides flexible packing methods and fool-proof rules. Production supervisors can print box codes in advance, and on-site workers can pack by scanning, with the system automatically recording and binding product information to ensure accurate packing. Fool-proof rules can be set based on materials, work orders, and workstations to avoid packing errors, and tracing functions can efficiently locate and resolve issues.
Before Application (BEFORE)
In the past, manual packing at Insta360 could sometimes result in mixed or wrong packing, leading to packing categories and quantities not meeting requirements.
The previous paper management was unable to accurately record packing information, making it difficult to trace the packing situation of products and affecting the efficiency and accuracy of product traceability.
After Application (AFTER)
Quantity fool-proof: The system sets a rule that requires scanning the correct quantity for packing to succeed, ensuring that packing quantities meet requirements and avoiding quantity errors.
Category fool-proof: The system sets rules based on product categories to ensure that the packed product categories meet requirements, avoiding mixing or wrong packing.
Tracing function: The system records packing information, achieving real-time recording and tracing of packing data, facilitating subsequent product tracing and management, thus improving tracing efficiency.
Interface Diagram
Single SN Scanning for Packing
Full Box Trigger to Read Full Box Weight Data
Product Data Package Link: A | Packing Management
5.1.4 Serial Number (SN) Management
Solution Introduction: The SN Serial Number solution aims to achieve systematic management and real-time tracing of Insta360's product serial numbers. Its characteristics include supporting diverse configurations, having fool-proof functionality and uniqueness verification, and enabling efficient and flexible SN full-process input scenarios. By real-time dynamically tracing the latest dynamics and location of each SN, this solution can achieve end-to-end recording of all inventory, production, inspection, etc., thus ensuring the accuracy and traceability of product serial numbers.
Before Application (BEFORE)
Lacking a unique serial number identifier, Insta360 could not accurately trace products' production, flow, and usage data, making tracing a tedious process requiring extensive paper documentation.
Without serial number identifiers, Insta360 finds it challenging to accurately identify and differentiate different products and semi-finished products, leading to assembly errors.
Insta360's product information records are incomplete, preventing a comprehensive understanding of product lifecycle and historical records.
After Application (AFTER)
Insta360 generates a unique serial number identifier for each product based on SN mapping rules, facilitating tracing and recognition while ensuring product uniqueness and traceability.
Records conditions of production, flow, and usage of products, achieving binding of finished product SNs with semi-finished SNs for fool-proof assembly calibration.
The SN serial number can trace every product's complete lifecycle information.
Interface Diagram
Single SN Scanning for Production
Single SN Scanning Production Fool-proof
Single SN Scanning Weight + Packing
Single SN Scanning for Weight
Product Data Package Link: S | Serial Number (SN) Management
5.1.5 After-sales Repair (RC)
Solution Introduction: The after-sales repair management solution achieves systematic management across the full process, including online recording of after-sales repair data, real-time tracking of after-sales progress, and independent management of after-sales work orders and work reporting pages to ensure orderly execution of after-sales processes. Additionally, the system records the entire disassembly and assembly process, ensuring the reliability and traceability of after-sales services.
Before Application (BEFORE)
The after-sales repair process records at Insta360 are incomplete, making it difficult to accurately understand the details and progress of each repair.
Simultaneously, Insta360 requires substantial manpower for manual recording and communication, leading to inefficiencies and a high error rate.
In the past, there were frequent occurrences of after-sales materials being mixed with regular materials, leading to disorder in work orders and confusion in processes that affected the quality of after-sales service.
Insta360 finds it challenging to trace after-sales repair operations and has poor traceability.
After Application (AFTER)
Insta360 utilizes the new hub cloud MES integrated with multiple systems, achieving full digital management across the process, recording after-sales repair data to ensure information transparency.
With online management, Insta360 can track after-sales progress in real-time, optimizing the follow-up of after-sales service.
Insta360 can establish independent after-sales work orders, set independent processes for after-sales materials, and prevent confusion and disorder in work orders and processes.
Recording the entire disassembly process enhances traceability in Insta360's after-sales repair process.
Product Data Package Link: S+ | After-sales Repair Management
5.1.6 End-to-End Traceability
Solution Introduction: The SN full process traceability solution covers the entire production process from procurement to inbound to finished product sales. With traceability supporting end-to-end tracing of each manufacturing step and related information of a single product, real-time management enables viewing and locating SN information, while post-process management supports both reverse and forward traceability, helping to quickly locate and manage issues in the production process.
Before Application (BEFORE)
Previously, Insta360 could not accurately record the production process and historical records of each product, which limited effective tracing of the product's origin, manufacturing process, and flow status.
On the production floor, it was difficult to obtain accurate information regarding a product's production status, quality condition, and lifecycle, affecting production decisions and quality control.
When quality issues or recalls arose in products, it was challenging to quickly locate the range and causes of affected products, leading to disputes and complications.
After Application (AFTER)
Insta360 records each product's operations from procurement inbound to finished product sales through the system, including production, inspection, packing, etc., enabling comprehensive traceability.
The production floor provides real-time and accurate operation information, helping production supervisors gain insights into each product's production status and quality condition.
In the event of quality issues or recall incidents, the system can quickly locate the range and causes of affected products, thereby mitigating the impact and loss.
Interface Diagram
SN End-to-End Traceability
Product Data Package Link: A | End-to-End Traceability
5.2 Gift Box Packaging Production Solutions
5.2.1 Workstation On-Site Management
Solution Introduction: Employees can quickly jump to the current work order and report work by scanning the SN code or batch code. The system sets multiple fool-proof scenarios, such as intercepting non-conforming products and avoiding duplicate scanning, ensuring production accuracy. Additionally, for complex electronic industry demands, the solution supports SN replacement, SN comparison, automatic SN printing, etc., enhancing flexibility and efficiency in production operations. The direct recognition of external SN barcodes also provides convenience for clients managing the MES system, eliminating the need to complete raw material SN/batch purchasing inbound through the operating system, allowing for seamless integration of the overall traceability process on the workstation page.
Before Application (BEFORE)
Unable to quickly and accurately locate the current work order and production tasks of employees, requiring significant time and effort in manual recording and searching for information, which reduced operational efficiency.
The manual assembly process is prone to errors, such as misreporting work orders, duplicate reports, and incorrect use of assembly materials, leading to inaccurate production data that affects FPY and OQC production quality indicators.
Lack of systematic fool-proof mechanisms affects capacity scaling.
After Application (AFTER)
Employees quickly jump to the current work order and report work by scanning the SN code, making the operation more convenient and efficient.
The system sets multiple fool-proof scenarios, including non-conforming products cannot be scanned past stations, SN/batch already scanned and reported at the current workstation cannot be scanned again, finished product SN not flowing to the current production position cannot be scanned, finished products of different work orders and lines cannot be produced together, and raw materials not assigned to the current work order cannot consume materials, ensuring the accuracy of operations.
Production continuity improves, with UPH capacity steadily increasing.
Scene Diagram
Single SN Production Reporting
Single SN Production Assembly Reporting Fool-proof
Product Data Package Link: A | Workstation On-Site Management
5.2.2 CCD Photo Verification Integration
Solution Introduction: The new hub cloud CCD vision capture device integration is based on the CCD vision capture device, which records test results via interfaces and intermediate forms. During the user's production reporting or inspection reporting phase, the control machine or phone synchronously displays the corresponding CCD captured data as a reference to guide and analyze production/inspection.
Before Application (BEFORE)
Previously, Insta360 equipment captured test images that existed solely in testing equipment, requiring manual entry into the system.
With numerous testing images on the production line, manual synchronization became cumbersome, affecting production cadence and delaying production.
Timely data entry for test results led to unreferenced reporting data, failing to meet expected production outcomes and causing quality issues.
After Application (AFTER)
Once the configuration of CCD integration parameters is complete, the device simply conducts the normal test and uploads the result data, making it convenient and efficient, with zero errors.
CCD testing images synchronize for review on the reporting page and production record, allowing production and management personnel to make swift production decisions.
Reporting records are tied to CCD testing results. By tracing reports through SN, CCD images can be reviewed, allowing for problem location.
Scene Diagram
MES and CCD Image Device Connection
Automatically collect weight data based on results to report qualifying or non-qualifying products.
Product Data Package Link: A | CCD Photo Verification Integration
5.2.3 Packing Management
Solution Introduction: The packing management solution provides flexible packing methods and fool-proof rules. Production supervisors can print box codes in advance, and on-site workers can pack by scanning, with the system automatically recording and binding product information to ensure accurate packing. Fool-proof rules can be set based on materials, work orders, and workstations to avoid packing errors, and tracing functions can efficiently locate and resolve issues.
Before Application (BEFORE)
In the past, manual packing at Insta360 sometimes resulted in mixed or wrong packing, leading to packing categories and quantities not meeting requirements.
The previous paper management was unable to accurately record packing information, making it difficult to trace the packing situation of products and affecting the efficiency and accuracy of product traceability.
After Application (AFTER)
Quantity fool-proof: The system establishes rules requiring scanning of sufficient quantities for packing to succeed, ensuring packing quantities meet requirements and avoiding errors.
Category fool-proof: The system sets rules based on product categories to ensure that the packed product categories meet requirements, avoiding mixing or wrong packing.
Tracing function: The system records packing information, achieving real-time recording and tracing of packing data, facilitating subsequent product tracing and management, thus improving tracing efficiency.
Interface Diagram
Product Data Package Link: A | Packing Management
5.2.4 Weight Verification
Solution Introduction: The new hub cloud's weight verification connects to weighing equipment, automatically collecting weight data and visually validating the results. By using a combination of software and hardware, users can efficiently collect weight data during the production/packing process, improving work efficiency in single and whole box weighing while ensuring effective fool-proof management throughout the process.
Before Application (BEFORE)
Manual recording of weight data is prone to missing or erroneous entries, resulting in incomplete and untraceable data during the production process, complicating quality management and issue tracking.
Lacking real-time monitoring and validation tools for weight data leaves the ability to detect and correct abnormalities during weighing processes diminished, reducing quality control.
After Application (AFTER)
Integration between the MES and electronic scales achieves automatic collection and validation of weight data, providing complete data traceability and ensuring data integrity and traceability during the production process, facilitating quality management and issue analysis.
Real-time monitoring of the weighing process enables the timely detection and correction of weighing anomalies, improving the real-time nature and accuracy of quality management.
Scene Diagram
Weight Verification
Product Data Package Link: B | Weight Verification
5.2.5 Serial Number (SN) Management
Solution Introduction: The SN serial number solution aims to achieve systematic management and real-time tracing of Insta360's product serial numbers. Its characteristics include supporting flexible and diverse configurations, possessing error prevention fool-proof functionality and uniqueness verification, and enabling efficient and flexible SN full-process input scenarios. By dynamically tracing the latest dynamics and location of each SN in real-time, this solution can achieve comprehensive records of all inventory, production, inspection, etc., thus ensuring the accuracy and traceability of product serial numbers.
Before Application (BEFORE)
Without a unique serial number identifier, Insta360 could not accurately trace the production, flow, and usage of products, requiring extensive paper documentation that is time-consuming and cumbersome.
Without serial number identifiers, Insta360 faced challenges in accurately identifying and differentiating different products and semi-finished products, leading to assembly errors.
Insta360's product information records remained incomplete, hindering accurate understanding of product lifecycle and historical records.
After Application (AFTER)
Insta360 generates a unique serial number identifier for each product based on SN mapping rules, facilitating tracing and recognition while ensuring product uniqueness and traceability.
Records conditions of production, flow, and usage of products, achieving binding of finished product SNs with semi-finished SNs for fool-proof assembly calibration.
The SN serial number allows full tracing of each product's lifecycle information.
Interface Diagram
Product Data Package Link: S | Serial Number (SN) Management
5.2.5 After-sales Repair (RC) (Pending April Update)
Solution Introduction: The after-sales repair management solution achieves systematic full-process management, including online recording of after-sales repair data, real-time tracking of after-sales progress, and independent management of after-sales work orders and reporting pages to ensure orderly execution of after-sales processes. Moreover, the system records the entire disassembly and assembly process, ensuring reliability and traceability of after-sales services.
Before Application (BEFORE)
The after-sales repair process records at Insta360 are incomplete and fail to provide accurate details and progress of each repair.
Simultaneously, Insta360 requires substantial manpower for manual recording and communication, leading to inefficiencies and a heightened likelihood of errors.
Previously, there were frequent occurrences of after-sales materials being mixed with regular materials, leading to disorder in work orders and confusion in processes affecting the quality of after-sales service.
Insta360 struggles with the traceability of after-sales repair operations, which suffer from poor accountability.
After Application (AFTER)
Insta360 utilizes the new hub cloud MES integrated with multiple systems to facilitate full digital management across the process, recording after-sales repair data for transparency.
With online management, Insta360 can monitor after-sales progress in real-time, enhancing the efficiency and timeliness of service follow-up.
Insta360 can set independent after-sales work orders with unique processes for after-sales materials, preventing confusion in work orders and processes.
By documenting the entire disassembly and assembly process, Insta360 improves the traceability of after-sales repair operations.
Product Data Package Link: S+ | After-sales Repair Management
5.3 Rework Order Management
Solution Introduction: The new hub cloud's rework order management provides independent management of the rework process, assigning unique processing steps and work orders for rework materials to ensure the orderly conduct of rework processes. It features a specially customized reporting page supporting recording specific data related to material disassembly, assembly, and repairs. Furthermore, the disassembly material tracking function leverages historical records and planned materials to prevent wrong disassembly and incorrect assembly, thus ensuring accuracy and reliability throughout the rework process.
Before Application (BEFORE)
Insta360 previously lacked clear rework order management guidelines, causing disorganized rework processes and difficulties tracking material disassembly, assembly, and repairs.
Incomplete records of rework processes made accurately tracing the source and handling of issues problematic.
Operators often executed rework without guidance, which led to mistakes like disassembly errors and mistakes in assembly, ultimately impacting product quality and production efficiency.
After Application (AFTER)
Establishing independent rework orders allows assignment of unique processing steps and work orders to each rework material, ensuring organized rework processes.
Specialized reporting pages enable recording of operations during the rework, such as material disassembly, assembly, and repairs, facilitating accurate data documentation and traceability.
Utilizing disassembly and assembly material lists enables fool-proof validation during the disassembly and assembly process to avert errors, thereby enhancing the accuracy and reliability of the rework processes.
Product Data Package Link: B | Rework Order Management
5.3.7 Full Process Traceability
Solution Introduction: The SN full process traceability solution covers the entire production process, from procurement inbound to finished product sales, supporting end-to-end tracing of each manufacturing step along with related information. During the process, management allows real-time visibility and tracking of SN information, and management thereafter supports reverse and forward traceability, aiming to quickly identify and manage issues within the production workflow.
Before Application (BEFORE)
Insta360 previously faced challenges in accurately recording each product's production process and historical records, which hampered effective tracing of products' origins, manufacturing processes, and flow statuses.
On the production floor, difficulties arose in obtaining accurate insights on product production status, quality conditions, and lifecycles, affecting production decisions and quality controls.
In cases of product quality issues or recalls, it became challenging to locate affected product ranges and reasons quickly, leading to disputes over responsibility.
After Application (AFTER)
Insta360's system documents every product from procurement to finished product sales, including production, inspection, packing, etc., thus enabling comprehensive traceability.
The production floor provides real-time, precise operation information, enabling production supervisors to clearly comprehend the production status and quality of each product.
In case of product quality issues or recall events, the system can rapidly pinpoint the affected product ranges and reasons, mitigating the impact and loss.
Interface Diagram
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6. Application Value
The Insta360 Innovation Factory has achieved remarkable results in digital transformation, with a comprehensive summary of these achievements presented below:
Implementation of fool-proof and error-prevention management for products: A highly efficient error-prevention system has been successfully implemented, ensuring correct assembly of accessories and preventing errors or omissions in gift box sets from flowing into the market. Additionally, detailed record-keeping of product serial number (SN) information provides reliable data support for product quality tracing.
Lifecycle control of host products: Comprehensive control has been established across all phases of host products, encompassing personnel, machines, materials, methods, and environments. This lifecycle management model enhances product reliability and market competitiveness.
Management of employee skills and working hours: Effective management of employee skills has been enacted, optimizing working hour allocation to ensure production efficiency and employee satisfaction.
Control of production costs: Monitoring and controlling production costs more accurately allows for real-time data analysis and cost forecasting, facilitating timely adjustments to production strategies and optimizing resource allocation, thereby lowering overall costs.
Synchronized interaction between production and testing software: Seamless integration between production systems and testing software allows quality master data and assembly master data to communicate easily, accelerating problem response times.
In summary, the digital transformation outcomes of the Insta360 Innovation Factory are significant, not only improving production efficiency and product quality but also optimizing cost control and employee management, laying a solid foundation for supporting the strategic goal of achieving 10 billion in three years.
