Two decades of success with inductors and EMC filters made in China

Over the past two decades, the Hongqi plant in China has evolved into a highly automated production facility and is today one of the largest factories of the TDK Magnetics Business Group. While the focus in the past was predominantly on standard products, the plant is now increasingly developing and manufacturing customer-specific solutions.

TDK currently employs about 5500 people in Hongqi and boasts 66,000 m² of space. A broad range of EPCOS products are made here, including wire-wound inductors, transformers, EMC filters for data and power line applications. The production of TDK's signal EMC filters began here in 2009. At this time Japanese production principles such as Monozukuri und Aru Beki Sugata were also introduced to foster the ability to manufacture excellent products on the basis of ideal processes. In the meantime, the plant manufactures three families of TDK common-mode chokes, which are used in motor vehicles to keep data transmission free from interference. Most of these products are shipped to Japanese automotive customers.

Figure 1:

Hongqi manufactures a broad range of products, including transformers, wire-wound inductors, signal EMC filters and power EMC filters.

Highly automated production and growing R&D

The plant invests constantly to improve its processes and stay competitive. Standards such as SPC (Statistical Process Control) and QRQC (Quick Response Quality Control) have been established to enable rapid intervention in the event of variations. The degree of automation is already high and is rising continuously. In particular, the use of robots is increasing. Today, a large number of highly skilled workers are employed in Hongqi, including a large share of engineers and technicians. Their job is to optimize processes, and adapt production workflows in keeping with the principles of Industry 4.0.

Figure 2:

The number of robots in the production lines is growing.

The site also has its own R&D department, which develops customized products that are manufactured in China – such as power EMC filters for Goldwind, one of the world's largest manufacturers of wind turbines and market leader in China. Goldwind itself recently provided proof of the excellent collaboration between the two partners, when it presented the EPCOS sales force with the Technical Cooperation Award 2016. In the future, Hongqi will also develop customer-specific products for the Chinese automotive market.

60 percent automotive, 60 percent exports

The factory currently ships some 800 million components a year. The automotive industry is the biggest customer, buying 60 percent of the products made in Hongqi. EPCOS transformers, for example, are used in the distance sensors that are fitted in parking assistance systems. Industrial electronics customers account for 30 percent of the components made here – including power EMC filters for wind turbines and transformers for micro solar inverters. The remaining 10 percent, for example, signal EMC filters, are shipped to information and communication technology customers.

Nearly two thirds of all the products manufactured in Hongqi are exported, mainly to customers in Europe and the NAFTA region.

Top logistics performance

Hong Kong, one of the world's largest logistics hubs where shipments are consolidated, is only a few kilometers away. Its good location in the booming Pearl River Delta industrial region means that the Hongqi plant can offer optimal logistics performance to its customers.

Moreover, this region in South China is home to many of the plant's suppliers, enabling the Hongqi plant excellent just-in-time sourcing and the best possible lead times.

Profile plant in Hongqi, China

Products

Inductive components

• Transformers
• Signal use inductors
• Power use inductors

EMC filters

• Signal EMC filters
• Power EMC filters

Certifications

• ISO 9001
• ISO/TS 16949
• ISO 14001

History