Sanzhi Heli Xichai Builds High-end Power for Heavy Truck Users
Li Suxiao, head of Xichai Heavy Machinery Department, said that the continuous production of Aowei engines is not only the hard work of employees, but also more importantly, “skillsâ€. It can be said that Xichai uses the wisdom of advanced planning, the wisdom of scientific management, the wisdom of the upper and lower, and the wisdom of three accomplishments to achieve the speed of “chi-made†Xichai in China, and provides the market with high-quality products. Advanced planning to provide "smart" equipment for high quality and high output "For the workers to do good things, they must first sharpen their tools." This ancient Chinese wisdom, in today's Xi Chai party secretary and director Qian Hengrong, has a unique understanding: "to build national brands, high-end power, equipment It is the foundation, the guarantee, and the key. The production of first-rate products must use world-class equipment." To this end, the Xichai Heavy Machinery Department consulted the construction standards of the world-famous engine factory as early as when it was planned to build, clarified the construction of the world's leading heavy-duty engine production base, and reached the “three lead†with advanced design, advanced equipment, and advanced management. The goal is to provide the most solid and powerful protection for Xichai’s “smart creationâ€. People who have been to the Xichai Heavy Machinery Department will invariably be impressed by its advanced production lines. In the production area of ​​50,000 square meters, the world's top equipment such as the German GROB machine tool, Swiss ABB robot, American GORBEL and so on can be seen everywhere. These devices integrate flexibility, integration, and automation into one. The automated assembly line has 179 stations, among which the FANUC robot is responsible for the assembly of the crankshaft. It can turn over 200 kilograms of components by turning it 360 degrees. The crankshaft is placed inside the machine and the whole set of movements can be completed at one go. Robostar three-axis robot is responsible for giving cylinders. The automatic gluing ensures the lubrication and quality of the cylinder liner assembly, and the entire line automation rate reaches 28%. 6DM machine line 60 process, the automation rate is as high as 78%. At the same time, the machining production line is also equipped with equipment that can fully analyze and control the machining accuracy and real-time control. The assembly line is equipped with automatic production lines for equipment such as tightening, gluing, conveying, and assembly, and is equipped with key dimensions, torque and appearance. Re-inspection equipment such as leakage. These equipments ensure that all aspects of product accuracy, reliability and production consistency can reach the international advanced level. In addition, the Xichai heavy-duty engine production line also set 6 domestic firsts, namely: China's first creative "X" type production line, to meet the non-adjacent three stations share a robot, reduce equipment investment, improve the utilization of the robot And production efficiency; the first use of three-axis robot to achieve automatic lubrication and automatic installation of cylinder liners; the first use of optical fiber sensing non-contact detection technology, to achieve the cylinder liner seal ring installation quality of anti-error detection, effectively guarantee the assembly quality; reduce labor The strength of the test, reducing the pressure of the manpower; the first use of visual error proofing technology to carry out error-proof scanning on more than 60 features of engine parts, control product defective product rate, reduce zero kilometer failure and 12MIS index; domestic first assembly line parts Full-site implementation of smart AGV automatic distribution concept. In 2016, Xichai's heavy-duty vehicle engine production base was selected as the 2016 Smart Manufacturing Pilot Demonstration Project by the Ministry of Industry and Information Technology. Li Dong, deputy director of the Ministry of Industry and Information Technology and Equipment Industry Department, investigated the field and found that Xichai has become a benchmark company for the “Made in China 2025 Project†with great promise. Scientific management adds “intelligent†power for high quality and high output The first-class intelligent equipment is the hardware guarantee for the production of high-end power. However, if the management is not good, the best efficiency will not be produced. The equipment will be no better. The success of many well-known companies in the world today comes from lean management. Although the Xichai Heavy Machinery Department has built an intelligent management system featuring intelligent dispatch, intelligent logistics, and intelligent logistic support, it has realized the life cycle data management of product development, manufacturing, and sales services. However, the annual design capacity of 75,000 units must meet the market demand and must be devoted to scientific management. Li Yuxiao researched and used Toyota's OEE/GAE and other production process analysis methods, and based on the actual conditions of production organizations, he innovatively created and implemented LTE efficiency analysis (a complete statistics and description framework for the production process) management method. Through LTE statistical analysis, employees can intuitively find the key processes and elements such as beat bottlenecks, quality stoppage bottlenecks, equipment stoppage bottlenecks, material waiting bottlenecks, and tool-impact bottlenecks for each production line. And basic data, to avoid the limited resources required to make it invalid or not urgently needed. Through analysis, it was found that the seal of the oil seal became the bottleneck of the entire line. Using camera shadows for troubleshooting, the beat was reduced by 8 seconds. The loss of Op25's tool change and tool change detection accounted for 6%. In the case of ensuring that the single tool cost does not rise, the cutting parameters do not decrease, and the tool life is improved, the employees are from the tool material, coating, angle 123, tool change tool, and auxiliary. Improvements such as tools and man-machine movements have reduced time loss to less than 4%. According to statistics, since the LTE system was put into operation, the LTE unit of the heavy machinery department increased by 3.8 percentage points year-on-year, the assembly line LTE increased 4.02 percentage points year-on-year, and the diesel engine production period shortened by 92.1 minutes. The total production line efficiency reached the leading level in the industry. Not only that, the heavy machine department also reengineers the process to be efficient and effective. Innovative application of “documentation, training, implementation†three-step analysis method, introduction of DMAIC analysis method, establishment of operation and delisting mechanism, etc., continuous improvement of various management processes, process reengineering to enhance management efficiency, setting a zero production safety accident, single cutter The industry-leading cost leads to an average annual drop in energy consumption of more than 25% for individual units, and quality indicators such as self-manufactured worker waste rate and zero kilometer failure rate all reached industry leading levels. Scientific management has effectively increased production efficiency, reduced production costs, and promoted continuous breakthrough in production capacity. In February 2017, the company produced 10,960 diesel engines. Its daily production capacity increased by 28% compared to 2016, and its production exceeded 10%. Production of cylinders and cylinder heads was 8,960 and 8,930, respectively, and the Nissan capacity exceeded 32%, which was satisfactory. Liberated market demand. Up and down the same desire for the national brand "intelligent" high-end power Intelligent equipment and scientific management are all external factors. If companies want to succeed, they still lack the key factor of “humanâ€. Xichang Party Committee Secretary and Director Qian Hengrong believes that Xichai can overcome one by one development problem and continue to maintain its leading position in the industry, relying on a highly qualified personnel team. In the heart of the Xichei people, there is a craftsman's heart, "focus, lean, and innovation," and we use our hearts to make the heart of the car. In recent years, more than 70 patents and patents have been awarded to China Automotive Engineering Society and FAW Group. Among them, there are 8 invention patents, 21 utility model patents, 2 software copyrights, and 5 enterprise standards for heavy-duty diesel engine intelligent manufacturing projects. The invention patent project of “Cylinder-body Water-proof Ring Installation Quality Error Detection and Protection Equipmentâ€, which was just granted a national invention patent in 2016, innovates the traditional manual detection method. By configuring a fiber-optic sensor, it automatically detects the installation quality of the water seal ring. The automatic online detection of equipment is realized, which effectively guarantees the assembly quality and reduces the cost of repairing the entire machine and the labor cost caused by the water seal ring problem. Acquired the "Assembly Process of an Overhead Camshaft Cylinder Head Assembly" of the FAW Group Patent Award Project, adopting advanced production technology to realize assembly, inspection and workpiece handling automation, and to increase the automation rate of the entire cylinder head production line. To 60%. According to Li Yuxiao, the Ministry of Heavy Machinery has achieved 9,771 items of proposals for the improvement of local existing materials in 2016, and the number of 9237 items implemented has reached 15 or more per capita. The department's QC team has completed 38 tasks such as "reducing the time of monthly failures of catenary equipments", "reducing the cold test rework rate caused by abnormal valve opening angles," and "improving the hourly output of 6DM school buses." The "School Hourly Output" topic, using the QC technique, solved the problem of the hourly output of 6DM school buses and won the first prize for the outstanding quality management team activities of the national machinery industry. In addition to the technical staff, the employees in the production line also actively started their brains and solved the problems in production. With regard to the continuous production of high monthly output, four shifts and three operations, the production mode of people stopping production has brought a severe test to the equipment. Through the analysis, the employees of the machine maintenance section searched for the equipment that is most prone to stop on the machine, and used equipment, lunch, and weekend time for equipment inspection and maintenance, so that the equipment failure was eliminated in the bud. In order to ensure high quality and high output, many employees gave up their holidays and gave up opportunities for reuniting with their loved ones. Some employees even had no rest for four consecutive months. Wisdom is the key to success. The wisdom-bearing Xichai people are using scientific management to maximize the effectiveness of smart devices and go all out to break the bottleneck, rush to the limit, create national brands, high-end power, and contribute to the Chinese automobile industry.
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