High end "wisdom" to make a look at Xugong
Xugong, it is a sign of the construction machinery industry, but also a pioneer of the representative, NPC and CPPCC just do something, Xugong to follow the Li Keqiang spirit of the meeting, will be made on the reform agenda, positive response to Prime Minister Lee about the development of manufacturing industry "China manufacturing + Internet".
The government report of the prime minister has pointed out the direction for the development of the manufacturing industry, and it is an inevitable move to promote the integration of industrialization and information. As a leader of construction machinery, Xugong Group actively responded to the national call, and built an intelligent, lean and green manufacturing system to push the enterprise towards high-end "intelligence".
Without a strong manufacturing industry, there will be no strong nation or nation. To build a manufacturing industry with international competitiveness is the only way to improve China's comprehensive national strength, safeguard national security and build a world power. Compared with the advanced level of the world, China's manufacturing industry is still large and not strong, and the gap is obvious in terms of independent innovation capability, resource utilization efficiency, industrial structure level, informatization level, quality and efficiency. The task of transformation and upgrading and leap forward development is urgent and arduous.
As a leading enterprise in engineering machinery, XCG has always been responsible for the revitalization of manufacturing in China. Xuzhou Mining Machinery Department (hereinafter referred to as XCMG excavators) to respond positively to the national call to promote the depth of integration of informatization and industrialization, with the concept of lean manufacturing process control, improve resource efficiency of energy use, building intelligent, lean, green manufacturing system, and promote the transition to high-end wisdom made enterprises.
Lean manufacturing - strict implementation process control
As one of the most important principles of lean production, standardization is a scientific solidification of the enterprise's excellent experience method, so that every person with professional skills can operate accurately according to the operation standard, so as to ensure the stability and reliability of the product quality.
The appearance quality is the most direct factor affecting the customer's first impression of the product. In Xuzhou digging machines, each piece should be carried out in strict accordance with the standard of painting: first use of professional equipment, Shotblast cleaning, descaling, surface dust, paint supply system through the accurate ratio of conveying paint spraying concentration reoccupy. The operating standard to each action spray into several points, the provisions of spraying order, spraying speed, spraying distance and other factors, workers have been training and drills, until uniform, consistent, accurate spraying action, so as to ensure the workpiece surface paint film thickness uniformity, smooth and bright, like a mirror.
Such harsh operating standards are not limited to the coating process. The establishment of technical standards, XCMG excavator operation specifications and operating instructions three level standard system, combined with lean Kanban, standardization, the whole manufacturing process of visual management. As the clone, each excavators perform the same standard, from parts to finished product process control, reliable results.
Dong Dandan is on the assembly workshop section chief, he must first go to check the balance box production plan according to the schedule before the opening day, will turn into the sequence of kanban. "The balance box is an epitome of visual visualization. Through the visual management of the full range of every employee can on the site of the human, machine, material, method and environment for real-time monitoring, production cycle is smooth, the implementation of standards is correct, the number is clearly within the specified scope, very convenient, fast and timely." Mention of lean manufacturing, Dong Dandan has his own understanding and keenly aware of.
"Kanban management", as well as standardized operations, is an effective use of lean ideas in the manufacturing field. With the construction machinery industry to accelerate the pace of restructuring, XCMG excavator continues to strengthen process control, promote the change and lean mode, optimize the demand management process, issued by SAP MES and accurate production planning, production site, and use Kanban sequencer balance box, FIFO (FIFO) implementation of Kanban production sequence pull production, improve the level of flexibility in manufacturing process, greatly shorten the manufacturing cycle, to meet the market demand quickly.
Based on the value chain of value-added operations and enhance the ability of cultivating management and manufacturing, XCMG excavator manufacturing technology innovation, the concept of lean manufacturing process into the depth, effectively enhance the overall level of lean management and operational performance, continue to promote the quality improvement and market breakthrough. In January 19, 2016, the twenty-second national enterprise management modernization innovation officially released, XCMG excavator exploration and practice of the "lean production management" construction machinery enterprises based on the value chain collaboration oriented project won the national enterprise management innovation achievement award.
Intelligent Manufacturing -- Deep promotion of "two integration"
Intelligent manufacturing is the main direction of the two depth integration. XCMG excavator since 2010 start information project, actively promote the integration of the development of a new generation of information technology and manufacturing technology, the intelligent management of the whole production process has been implemented.
Based on SAP system, the manufacturing execution system as a link, realizes the intelligent equipment XCMG digging machine network, implement real-time monitoring and visualization management of the manufacturing process, using computer simulation techniques to analyze and monitor data judgment and decision making, and using a lot of welding robot, CNC machining centers, automatic painting line and assembly line other equipment, intelligent manufacturing equipment accounted for more than 90%, to achieve the automation, flexibility and less humanized production.
XCMG digging machine dug in joint manufacturing workshop in Jiangsu province is the first demonstration of "intelligent workshop", here has the most advanced automation industry boom flexible welding line, realize the whole process of unmanned operation fixture, welding, unloading, transport, with the quality of intelligent monitoring system, HD closed-circuit television monitoring system and intrusion prevention system that only 2 people can operate the entire production line and efficient operation, the traditional mode of operation, requires 20 people.
Entering the welding monitoring room of the boom, Fang Rongchao, the welding technologist, opened the central control computer control software, and the entire production line clearly appeared on the monitoring interface. A robot wired the mechanical arm, and a RGV transmission vehicle was running on the track. "This is the arm welding real-time state diagram line panorama, if abnormal equipment, alarm system immediately," he click on the appropriate icon, an information interface jumped out, "this is the robot of welding current and welding time, the workpiece number data are recorded, archived data for each welding workpiece, process control traceability."
In the field of production XCMG digging machine, information technology has been applied to every corner of the APP terminal mobile phone newspaper industry system is a typical example. The system of the production process execution management system through the wireless network (MES) and mobile phone terminal link, workers simply sweep the two-dimensional code to get the workpiece on the workpiece number, manufacturer and other information in the production line process is completed in real-time information processing, and transmitted to the MES management system, managers can understand the real-time production schedule and quality control, accurate and efficient.
Green Manufacturing - the practice of sustainable development
Sustainable development is the key point of building a powerful manufacturing country. XCMG excavator closely around the national strategic direction, the construction of green manufacturing system, the construction of environmental protection coating workshop, assembly workshop clean production line, and actively promote the implementation of product remanufacturing, excavator parts recycling, improve resource utilization efficiency.
In Xuzhou excavator painting workshop, dust and paint mist through the circulating water system, adsorption, precipitation, to the Environmental Protection Agency for processing organic waste through professional equipment recycling and converted into harmless gas discharge plant, to achieve low emissions of dust, effectively avoiding the environment pollution. Workers wear professional protective clothing and respirator, which can effectively separate solid dust and harmful gas, and the circulating air system continuously conveyed fresh air to the workshop, which ensures maximum health operation.
The remanufacturing workshop is a different scene. A waste components placed in the area to be repaired, and a new remanufacturing lined up in the debug area, after technological transformation of remanufacturing, waste parts became "old" into treasure take on an altogether new aspect in quality and performance, not only do not lose in the new, but also can save the cost of 50%, saving 60%, saving material 70%.
With the hydraulic cylinder manufacturing as an example, according to the traditional renovation or repair, the piston rod against and scratches to ensure cylinder seal must be replaced by pulse welding, XCMG excavator nano composite electro brush plating and manufacturing technology of piston rod injury to repair the advanced recovery, size and surface of the piston rod the quality is, after the repair of piston rod performance and life with the new, even beyond the wear resistance of new products, while less than half of the new. At present, XCMG digging machine has established the remanufacturing business process and improve the standard system, focus on the development of remanufacturing engine, hydraulic motor and other key components.
The deep integration of the new generation of information technology and manufacturing industry is triggering far-reaching industrial changes, forming new mode of production and industrial form. In promoting the intelligent production processes, lean, accelerate the transformation and upgrading of green manufacturing journey, XCMG excavator has taken a critical step. In the future, XCMG will continue to enhance the enterprise R & D, machine production, management and service of information and intelligence level, improve the utilization efficiency of manufacturing resource, strengthen product lifecycle management to build a green, green manufacturing system of lean, intelligent and efficient, contribute in manufacturing power to promote the transformation of in the manufacture of power.
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