力山工業股份有限公司

REXON INDUSTRIAL CORP.

Founded in 1973, REXON INDUSTRIAL CORP. is a publicly listed company operating in the mechanical, electrical, and electronics industries. With approximately 1,500 employees and operations in mainland China, REXON focuses on two main product categories: fitness equipment and machine tools. REXON is Taiwan’s largest DIY machine tool manufacturer, exporting primarily to the US and Europe.

Products:

Fitness Equipment: OEM production of elliptical trainers, exercise bikes, treadmills, recumbent bikes, and more.
Machine Tools: Primarily OEM/ODM of electric woodworking machines and power tools, with a growing focus on its own brand.

ManufacturingBottleneck

1.Manual calculation and communication of material needs across plants is labor-intensive.

2.Tracking conforming items within outsourced inventory (including defects) is challenging.

3.Lack of visualized production data hinders informed scheduling decisions.

4.Unsynchronized schedule changes and related documents complicate progress tracking.

5.Lack of production and maintenance traceability hinders progress monitoring.

6.Per-container material issuance creates inventory discrepancies.

7.Inconsistent inbound/outbound flow causes inventory discrepancies.

DigiHua IntelligentSolution Implementation

Optimized scheduling and material planning.

Challenge

Material usage and demand across multiple plants are calculated and communicated manually, consuming significant manpower.

Solution

Revise the existing system logic (original in-house planning was based on forward scheduling from “NOW” → changed to backward scheduling from the assembly requirement date to determine in-house dispatch dates). Establish multi-plant scheduling and material preparation logic, as well as internal and external production allocation rules, enabling the APS system to automatically generate scheduling plans and material requirements.

Multi-plant material management.

Challenge

Solution

Redefine delivery lead time simulation days based on product process and customer tier to distinguish whether the customer is forecast-based or not.

Improved production progress tracking.

Challenge

Solution

Enhanced material status management.

Challenge

Solution

Digital first-article and patrol inspections; real-time exception alerts; automated report generation.

Challenge

Before inspection, personnel must manually review QC engineering drawings to confirm inspection items and standards, then record the results on paper. One inspector is assigned to inspect only one unit (welding), spending about 90 minutes daily on inspection execution and paper recording.
Paper-based inspection records are later entered into Excel for statistics, requiring an additional 45 minutes per day.
When abnormalities occur, there is no notification function, making it impossible to promptly respond to production process issues.
Quality problem analysis and data retrieval are time-consuming.

Solution

The system provides predefined inspection items, reducing search time and improving efficiency. Two inspectors can now perform inspections across four units (machining, stamping, welding, and plastics), completing inspection execution and system-based recording in about 60 minutes per day.
Electronic inspection records enable systematic data retrieval without redundant data entry.
Inspection rules and standards are automatically applied — when deviations or violations occur, alerts are displayed, and in severe cases, abnormal reports are generated to prevent defective products from passing through.
A Pareto chart summarizes defect types, enhancing the efficiency of quality issue analysis.