In the intelligent control room, the production status of several computers, a wall display screen and the workshop production line is presented in real time, and the production dynamics of each car are clear at a glance. This is the intelligent management of this factory. It not only greatly improves the production efficiency, but also improves the product quality to a new level.
But in the "running-in" of intelligence and handcraft, "giving up" is a necessary step. It not only abandons the original mode of production and workflow, but also abandons the inherent mode of thinking and production concept. Then, in the process of "going out of the building", how did Foton Motor Shandong Multifunctional Automobile Factory complete the intelligent transformation from operation to thought? Let's get into their daily work and find out the answer.
Here comes the machine-unemployment first, re-employment, and promotion of people and products.
Li Yongjun used to be a sorter in the assembly workshop. Because the factory is mixed-flow production, there are often five product platforms running at the same time on the production line. His job is to sort out the products of the joint production line. "If you don't pay attention, the whole production line will stop. Really stressful! " Li Yongjun sighed.
Now, the machine has come, the information system has realized automatic sorting, and manual sorting has become a thing of the past. Efficient computing accurately arranges one package and one distribution on this most complicated production line in China, and the accuracy rate can reach 100%.
So, Li Yongjun lost his job, but he was happy. "I don't have to worry about my mistakes causing losses to the factory anymore. Now I am in a new position, learning new skills, and my brain is liberated from a cumbersome and high-pressure state. "
On the intelligent production line, a small bar code allows the machine to accurately sort materials, automatically turn off the information, and the material reserve information will closely match the production rhythm of the next day. A coarse row and a fine row can arrive at the production station accurately with the cooperation of the transfer vehicle which also carries the production information. At the same time, there are bar codes, which are used for information tracking, data storage, statistics, analysis, recording and tracing.
In the workshop, near the production line, there is a display screen at intervals, showing the production status of each station. When there is an abnormality in the production site, the production personnel can make a phone call through the Andon button, and the relevant personnel will respond and handle it and resume the production line. Through the construction of the visualization system, the factory realized the visualization of the production process and greatly improved the speed of handling abnormal problems.
"Informatization has achieved prepared production, adjusted and optimized the personnel structure, and the production arrangement is more accurate." Liu Fengjun, general manager of general assembly, said, "After the information system goes online, one person can save 50,000 yuan a year and shorten the downtime by nearly 80%".
"Informatization has also improved product quality," said Zhang Jimin, director of the factory. "The first pass rate of the final assembly line has increased by 60%." Thanks to the intelligent drive of the equipment, problems can be prevented in advance without going offline. Through the interconnection of vehicle information and intelligent equipment in production line, the factory can collect the running state of the equipment in real time and guide the efficient operation of the equipment. Even if the body error is only a few tenths of a millimeter, the equipment can accurately identify it and then call the police. According to the recording and analysis of "alarm" information, further improve and adjust the equipment to ensure the smooth progress of the production line.
On system coding "zero error", efficiency and quality * * *
As an employee of the engine packaging production line, Zhao Zhiwei also bid farewell to his past working condition. Before, he often worked overtime with his colleagues, assembled parts in advance and stacked them next to the production line to ensure that he could keep up with the production rhythm the next day. Now, such days are gone forever.
Changes of manufacturing execution system (MES system) in factory production line. MES system integrates production scheduling, product tracking, quality control, fault analysis and other management functions. On a unified platform, complete closed-loop production is realized by optimizing the manufacturing process. After the system goes online, the plan is accurate and the parts are delivered in time. Zhao Zhiwei and his colleagues only need to assemble the parts according to the plan, which is enough to meet the production demand.
Qin Wang and Wang Zhen also changed their working status because of MES system.
Before the MES system was put into production, Qin Wang was a workshop planner, responsible for numbering 17 VIN code. After numbering, it was sent to the printing station of the production line, where Wang Zhen entered the code into the computer and printed it out. The vehicles produced by Shandong Multifunctional Factory cover more than 100 states, and Wang Zhen outputs 130- 140 VIN codes every day. Once there is a problem, the vehicle cannot be listed.
After the MES system runs, the system will automatically generate the VIN code from the moment the order is received, which saves the links of manual coding and manual input. Wang Zhen can only print the VIN code by clicking the OK key.
For a long time, all car body scheduling schemes have been formulated by special personnel, and the matching VIN codes are also output manually, which is related to the correct matching of parts. From coding to engraving, there are two manual inputs, which is a risk point that only responsibility can prevent. If the code of a landscape G7 is wrong, two people will disassemble and reassemble the parts in one hour, which is a great waste.
However, since the MES system was launched in July, 2065438+2006, the automatic intelligent VIN code printing has achieved zero errors. At the same time, the on-line and off-line code scanning system also realizes real-time feedback and real-time monitoring of vehicle status, achieving the purpose of improving efficiency and reducing costs.
Nowadays, customers scattered all over the world can place their own orders as long as they open the computer terminal and log in to the order system of Shandong Multifunctional Automobile Factory. Whether you customize a new model or add new equipment, as long as you can choose from the system and click the OK button, customers only need to wait for the arrival of a new car.
Moreover, the order system can also automatically evaluate and classify orders, arrange the 24-hour uninterrupted production of orders, and arrange the production of car body, painting and final assembly by the system, which fully realizes the "7-3" scheduling cycle (7 days for material preparation and 3 days for production delivery), which can minimize the waiting time of customers.
Smooth service-real-time tracking, customers and factories are assured.
Gao Feng, deputy manager of production efficiency and IE department, is one of the "pioneers" of intelligent production management in the factory. From knowing nothing about intelligence, I can now introduce the application of intelligence in each section of the workshop in detail, and I can imagine the effort and hard work.
"At first, everyone just outlined the general appearance of intelligence according to their own imagination, and then added details bit by bit. After nearly two years of revision, we finally have the current layout. " In Gao Feng's words, intelligence is not static, and its internal functions are constantly upgraded and improved.
The convenience brought by intelligence is not only reflected in workshop workers, but also a qualitative leap for factory customers.
Now customers want to know the production information of vehicles after placing an order, so they don't need to call again, and they won't get vague answers like "probably" and "almost". As long as he enters the "single number" of the vehicle he wants to inquire on his mobile phone or computer, the production and transportation information of the vehicle will be presented to him immediately.
Tracking real-time logistics information like email, a single number can let customers know the online status of vehicles at any time. For customers, it is natural to rest assured that there is no need to worry about how the vehicle is produced and when it will be delivered. For the factory, the car number can not only help to inquire about the production process of the vehicle, but also quickly trace back according to the car number when the vehicle fails, so as to find the cause of the problem and solve the problem in the shortest time, instead of "grasping" the inspection bit by bit as in the past, and the efficiency is greatly improved.
This two-way convenience makes the communication between customers and the factory smoother, avoids unnecessary troubles caused by information asymmetry, and also increases customers' trust in the factory.
Many changes-once the information is available, the device and I will be relieved.
Xie Xianjun, the monitor of the painting and calligraphy class, and his colleagues no longer have to work overtime every day.
In the past, the daily production capacity was more than 200 vehicles, and I had to work overtime until eight or nine in the evening. Now the production capacity is unchanged, and it can be easily completed from nine to five.
Thanks to Li, the workshop director of the paint department, and the information transformation of the team.
In the information transformation, 3C2B wet-to-wet process replaced the traditional coating process. Taking the two-color landscape vehicle as an example, after adopting new technology, the running time of the equipment is reduced, and the process of drying and polishing the top coat is omitted, which not only greatly improves the production efficiency, but also saves 70 1 10,000 yuan every year.
In the paint department, busy robots are a beautiful "landscape" in the workshop. These robots are scattered in all sections of the production line, and each robot is a "generalist" who can spray middle coat, top coat and top coat, and it is inseparable from several programming experts in the factory.
There are more than a dozen models in general automobile enterprises, but for the convenience of production, as early as 20 12, 7-8 employees with strong learning ability were arranged to follow up equipment debugging and learn plagiarism programming in the factory. These masters who are proficient in copy programming enable the robots in the workshop to adjust the program at any time as needed and complete the modification of various models.
The addition of robots not only changes the workshop efficiency, but also ensures the product quality. The perfect integration of man and machine has also opened a "new blueprint" under intelligent manufacturing.
Intelligent manufacturing not only changes the traditional production mode, but also improves the quality and efficiency. In 20 16 years, the factory manufacturing cost was reduced by 26.99 million yuan and 2014.84 million yuan; In two years, the number of employees decreased from 2433 to 1992; At the same time, the production quality is improved by about 10%.
Futian Shandong Multifunctional Automobile Factory uses the Internet of Things and monitoring technology to strengthen information management from the perspectives of intelligent equipment, intelligent logistics, intelligent procurement and intelligent management, and completes the optimal allocation of people, machines and resources through innovation and value-added, so as to create a green, efficient, energy-saving and comfortable intelligent factory.
Million car purchase subsidy