On-Site Excellence: High-Volume Valve Repair & Retrofit at Ningbo Xusheng Delivering Rapid Turnaround and Precision Upgrades for a Leading Automotive Component Manufacturer

On-Site Excellence: High-Volume Valve Repair & Retrofit at Ningbo Xusheng Delivering Rapid Turnaround and Precision Upgrades for a Leading Automotive Component Manufacturer

Introduction
Ningbo Xusheng Auto Technology Co., Ltd. (603305.SH), a prominent supplier to global electric vehicle manufacturers, relies on highly automated production systems. The performance of hydraulic systems—especially critical proportional and servo valves—directly impacts production efficiency and part quality. When faced with frequent valve failures and prolonged downtime, Xusheng partnered with our team for a large-scale on-site repair and retrofit initiative.

The Challenge
Xusheng’s die casting and machining lines use numerous high-performance valves that control precision movements. Over time, these valves developed issues such as:

Drift in proportional pressure and flow control

Slow response and inconsistent clamping/injection performance

Contamination-induced failures and seal degradation

Long lead times for replacement parts affecting production schedules

The client needed a solution that would:

Minimize machine downtime

Restore valve performance to OEM standards

Introduce modernized components for longer service life

Provide on-site technical support for minimal disruption

Our Solution: On-Site Valve Repair and Retrofit Program
Our engineering team executed a full on-site service campaign at Xusheng’s facility, including:

1️⃣ Diagnostics & Evaluation

Systematic testing of all main and servo valves in die casting machines and automation units

Identification of failure root causes: contamination wear, solenoid burnout, spool corrosion, and seal failures

2️⃣ High-Volume Repair

Repaired over 120 valves including:

Proportional pressure valves

Servo-proportional directional valves

Cartridge and pilot-operated check valves

Processes included: ultrasonic cleaning, lapping, recoiling, reassembly with OEM-grade kits, and full recalibration

3️⃣ Retrofit and Modernization

Where appropriate, older valve models were replaced with newer-generation equivalents for better performance and compatibility

Custom manifolds and mounting adaptations designed to drop into existing systems

4️⃣ On-Site Testing and Validation

Each valve was tested on portable test benches simulating real operating conditions

Valves were verified for:

Hysteresis < 3%

Repeatability ±0.5%

Rated flow and pressure at 95%+ efficiency

5️⃣ Training & Knowledge Transfer

Conducted maintenance workshops for Xusheng’s technical staff

Delivered valve maintenance best practices and contamination control guidance

Results Delivered

✅ 85% Reduction in Valve Downtime: Most valves repaired and returned within 48 hours

✅ ~60% Cost Savings compared to new valve replacements

✅ 30% Improvement in Response Time on retrofitted hydraulic circuits

✅ Enhanced System Longevity with upgraded seals and materials

✅ In-House Capability Built through training and documentation

Client Feedback
“We were impressed by the speed and skill of the team. They transformed our maintenance approach from reactive to proactive. Repairing valves on-site allowed us to avoid weeks of downtime and gave us more control over our equipment health.”
— Maintenance Manager, Ningbo Xusheng

Why Choose Our On-Site Valve Services?