1.June 5 morning
We arrive at Liugongmen at nine in the morning. First of all, Mr. Huang showed us the exhibition hall of Liugong products and introduced Liugong products to us. The sales of loaders, excavators, rollers, pavers, forklifts and other products are among the best in the industry, which reflects the strong technical strength of Liugong.
Later, Mr. Huang led us to visit all the factories of Liugong, which gave us an overall understanding of Liugong's production.
On the afternoon of June 5,
Visit the heat treatment plant and tool factory in the afternoon.
There are many large heat treatment machines in the heat treatment plant, forming a fully automatic heat treatment production line, which can complete various heat treatment processes, including normalizing, tempering, tempering, annealing, straightening, carburizing, nitriding and cleaning. Every equipment is equipped with safety protection, and safety warnings can be seen everywhere on the wall and bulletin board, which reflects Liugong's emphasis on safety production.
Then we visited the tool factory. What impressed me most here was the earnest attitude of the workers. A large group of us looked around the machine tool, but all the attention of the workers was focused on the parts they were processing, as if they had never found us around. I think the development of Liugong is inseparable from such an admirable group of workers. Here, we have closely observed various machine tools, including lathes, milling machines, drilling machines, wire cutting machines, CNC lathes and other traditional and advanced processing equipment.
3. On the morning of June 6th
Visit the gearbox factory in the morning.
Let's first enter the big workshop that produces gearbox cases. Equipment has special machine tools and combined machine tools. The fixture adopts special fixture to reduce clamping time and improve production efficiency. The special machine tool is characterized by high machining efficiency but low precision, so the combined machine tool of machining center is used to make up for its deficiency. For example, on the modular machine tool, the principle of single-sided two-pin positioning, hydraulic clamping and three-sided multi-tool machining is adopted. The micro-process of box processing is as follows: finish milling sleeve surface and end cover surface-milling small pump surface and control surface-drilling and boring-rough boring-semi-finish boring-boring groove-fine boring/machining center fine boring-drilling I- tapping II- boring, drilling-drilling and tapping-cleaning.
The small parts workshop produces gears, pump wheels and spiral bevel gears of gearbox. There are many machine tools used to process gears in the workshop, such as hobbing machine, grinder, drilling machine, coordinate boring machine, differential gear milling machine, copying lathe, broaching machine, slotting machine, machining center, CNC lathe, common lathe and so on. In addition, many accessories are needed, such as flanges, shafts and other parts. Box factory adopts the advanced enterprise production management concept-U-shaped line theory for production management, which was first put forward by the Japanese and applied to enterprise production practice. U-shaped line is a production line with many varieties and small batches, and the primary goal is to reduce the waste of manpower and material resources. U-shaped production line must put the input point of production (that is, the placement point of materials) as close as possible to the output point of finished products, which we call "IO consistency" principle. That is to say, when the input point is close to the extraction point, the waste of "return" time can be avoided. In order to achieve the principle of IO consistency, the layout of the production line is U-shaped like English letters, so it is called "U-shaped production line". IO consistency principle can be used not only in the layout of production lines, but also in the design of machinery and equipment. The same primary purpose is to save manpower, smooth logistics and eliminate waste. According to Mr. Huang, since the U-shaped line theory was adopted in 2008, the production cost has been reduced by one third in half a year and good economic benefits have been achieved.
In addition, on the wall in front of the workshop, we also saw Liugong's production management theory, that is, the six-horse theory. Six Sigma is an efficient enterprise process design, improvement and optimization technology, which evolved from the total quality management method proposed by GE in the mid-1990s, and provided a series of new product development tools that are also suitable for design, production and service. Then keep pace with GE's globalization, service, e-commerce and other strategies, and become the most important strategic move for enterprises pursuing excellent management in the world. Six Sigma has gradually developed into a management concept of taking customers as the main body to determine the strategic objectives of enterprise and product development and design, and pursuing continuous progress.
6σ management method is a statistical evaluation method, the core of which is to pursue zero-defect production, prevent product liability risks, reduce costs, improve productivity and market share, and improve customer satisfaction and loyalty. 6σ management not only pays attention to the quality of products and services, but also pays attention to the improvement of processes. "σ" is a letter in Greek, which is statistically used to represent the standard deviation value and describe the deviation degree of individuals from the mean value in the population. The measured σ represents the probability of unit defect, million defects or errors, and the greater the σ value, the less defects or errors. 6σ is a goal. This quality level means that 99.99966% of all processes and results are defect-free, that is to say, 1 10,000 things have been done, and only 3.4 of them are defective, which is almost close to the most perfect state that human beings can achieve. 6σ management pays attention to the process, especially the core process of providing value to the market and customers. Because the process capability is measured by σ, the greater σ, the smaller the fluctuation of the process, and the stronger the ability of the process to meet customer requirements with the lowest cost loss and the shortest time period. According to the 6σ theory, the operation of most enterprises is between 3 σ and 4 σ, that is to say, every million operation errors are between 62 10 and 66800. These defects need to be remedied or corrected by the operator after the event with 15% ~ 30% of the sales. If it reaches 6σ, the funds to be remedied after the event will be reduced to about 5% of the sales.
To achieve 6σ, we must first formulate standards, track the deviation between assessment operation and standards at any time in management, and constantly improve, and finally reach 6σ. At present, a simple process model has been formed to continuously improve each link: definition, measurement, analysis, improvement and control. It is reported that Liugong has achieved very good economic benefits after adopting this theory.
On the afternoon of June 6th.
In the afternoon, we visited the drive axle factory. The functional characteristics of the drive axle are bearing, driving, differential speed and braking. Here we come into contact with the so-called "5S" standard. "5S" is the abbreviation of Seiri, Seiton, Seiso, Seiketsu and Shitsuke. Because the first letter of romanization of these five words in Japanese is "S", it is called "5S" for short. The "5S" activity originated in Japan and was widely implemented in Japanese enterprises, which is equivalent to the civilized production activities carried out by Chinese enterprises. The object of "5S" activity is the "environment" of the site. Considering the overall situation of the production site environment, practical plans and measures are formulated to realize standardized management. The core and essence of "5S" activity is self-cultivation. Without the corresponding improvement of employees' self-cultivation, it is difficult to carry out and adhere to the "5S" activities. According to Toyota's management content, "5S" has become the basis of quality management, and quality management should be based on "5S" management.
On the morning of June 7th.
In the morning, we visited the foundry. What impressed me most was the pungent smell in the factory. The production line here also conforms to the U-shaped line theory and has high efficiency. The column of the main defect reason in the scrap record of a casting in the modeling workshop is recorded as: "Sand inclusion (9 times); Blowhole (1 time) ",it can be inferred that the main cause of casting defects in the actual casting production in the factory is sand inclusion, so special attention should be paid to this problem in product design, process planning and workers' production operation to reduce the rejection rate.
Next, we visited the component factory. Most workers here are engaged in welding. There are some common welding defects in the welding process of the wall display board in the welding workshop, such as sparks splashing, burning through, welding slag not being removed, welding burr, uneven weld seam, air holes and so on. And some corresponding preventive measures. The processing equipment here includes TCBAR column moving horizontal machining center, plasma wire cutting machine, shearing machine, forging press, CNC plasma cutting stepping punch, CNC flame cutting machine and other large advanced equipment. It can be seen that the production mode of structural parts is to cut the plate first and then weld it.
On the afternoon of June 7th.
In the afternoon, we came to another factory in Liugong.
First, I went to the hydraulic parts factory. The piston rod is produced by friction welding. Here we observe the whole process of friction welding for the first time: one part is clamped and fixed, and the other part rotates at high speed driven by the spindle. The heat generated by the relative friction between the two parts quickly melts the contact surface, the rotating part stops quickly after a period of time, and then the weld is wrapped with asbestos cloth for a period of time.
Then, we entered the piston rod surface treatment workshop. Here, the chromium plating on the piston rod surface is mainly completed, and the process flow is: fine grinding the excircle-inspection-polishing before plating-chromium plating-inspection after chromium plating-inspection. Chrome plating adopts electroplating method, and there is electroplating pool in the workshop.
From the hydraulic parts factory, we went to the sheet metal parts factory. The main processes of sheet metal parts factory are scribing, cutting, deburring, forging, welding and painting. For some thin plate parts, the process from steel plate to parts is basically completed here, such as the shell of loader. There is a high-tech diaphragm painting equipment production line in the workshop, from installation, delivery, painting and drying, all in one assembly line.
(2) Gaohua Machinery Co., Ltd.
6 July morning 1 1
In the morning, we came to Gaohua Machinery Co., Ltd. in Liu Dong New District, which is much smaller than Liugong's, and the production process of products is almost carried out in one factory. Here mainly for automobile stamping die,
Design and manufacture of jigs and fixtures, and production of auto parts.
Due to the power failure today, Gaohua Machinery Co., Ltd. can only use its own power supply. Due to the lack of electricity, it is impossible to carry out large-scale production activities. The receptionist mainly explains the company to us. The company has sales department, technical department, quality department, mold department, parts department, finance department and other important departments.
The technical department is mainly responsible for the design of automobile stamping dies, fixtures, checking fixtures and other tooling, and formulating various process documents and operating standards. Based on AutoCAD, UG and AutoForm, a set of perfect design specifications for molds, fixtures and checking fixtures is established. Ensure that the unit has strong market competitiveness in technology and development management.
The quality department is mainly responsible for the quality management of automobile stamping dies, fixtures, inspection tools and automobile parts. Establish a set of perfect quality management procedures and standards for molds, fixtures, inspection tools and auto parts. The mold department is mainly responsible for the manufacture of molds, fixtures, checking fixtures and other tooling. Equipped with CNC milling machine, general milling machine, grinder, drilling machine and other processing equipment, 600-ton hydraulic press and other mold debugging equipment, as well as three-coordinate measuring instrument and other measuring equipment. It not only provides a strong guarantee for the development of auto parts in this unit, but also provides design and manufacturing services for auto stamping dies, fixtures and checking tools for the market.
The parts department is mainly responsible for stamping and welding production of automobile parts. It is mainly equipped with stamping equipment such as 630-ton oil press, 500-ton oil press, 365,438+05-ton oil press and punch press, as well as welding equipment such as vertical spot welder, suspended spot welder and CO2 shielded welder.
The company has 336 employees, including 45 engineers, 82 fitters in the mold department and 0/73 in the parts department. The models involved in the development include Nissan X 1 1M project, Toyota 930L project, Suzuki YP6 project, Wuhan Shenlong T33 car project, X7 car project, T73 car project, SAIC-GM-Wuling SPARK mini-car, Wuling light series mini-car, Wuling Hongtu, N300L mini-car, CN 100.
Since its establishment, Gaohua has been adhering to the business philosophy of "exquisite life, high-quality products and honest society" and implementing the business policy of "cultivating talents, excellent technology, perfect quality and win-win market", and has passed the international quality system ISO/TS 16949 certification.
We also found that although the enterprise is a relatively young medium-sized private enterprise, the factory management is relatively standardized, because the factory area is relatively new and the working environment is relatively good. Moreover, the factory has a slow pace of work, good welfare, providing accommodation and buying hardware, so it also attracts a group of talents to join. When we visit, we
It was also found that employees from Japan worked in it.
According to the employees of this company, their factory management adopts "6S" standard, that is, safety in production is increased on the basis of "5S" sorting (Seiri), rectification (Seiton), cleaning (Seiketsu) and literacy (Shitsuke). This reflects the innovation of private enterprises in China in enterprise management methods and concepts.
(3) Liuzhou Huaqing Construction Machinery Company
June afternoon 1 1
In the afternoon, we came to Liuzhou Huaqing Construction Machinery Co., Ltd., a small private enterprise. Is a professional enterprise engaged in supporting production of loaders, excavators and graders, various agricultural machinery manufacturing and photo album manufacturing, and also undertakes various outsourced processing and production. According to an old employee who has worked in the company for six years, the company is contracted to individuals. There are five factories, but only one factory is in use at present. There are less than 20 employees in this factory, and the eight-hour work system is piecework. Due to the poor efficiency of the company, the wages of workers are low.
The processing equipment of our company is TX 611C/1W horizontal boring machine, T6 17 horizontal boring machine, T6 1 1A horizontal boring machine and Z9050x/KLOC. B 1-43 arc milling machine C5 12 single-column vertical lathe, etc. , are very old and outdated equipment, including TX 611C/1W horizontal boring machine, the machining accuracy can reach a trace.
During our visit, we not only found that the equipment was backward, but also found many problems, such as: the ground was dirty and the treated iron filings were not cleaned up in time; Machine tools, materials, etc. They are not neatly placed and there is no regional management; Problems such as backward and irregular management. Management is not as good as previous enterprises, which just reflects the importance of advanced management.
Liuzhou Liuhe fangsheng machinery co., ltd
9.6 am12
The last stop of our internship was Liuzhou Liuhe Fangsheng Machinery Co., Ltd. Now we mainly produce supporting products for Dongfeng Liu Qi, SAIC-GM-Wuling, FAW Liute and Yuchai construction machinery, and the products involve commercial vehicles.
MPV passenger cars, cars, mini-cars, construction machinery.
The company's production also adopts advanced management mode with high production efficiency. Sheet metal stamping is completed continuously in one production line from blank to finished product. Advanced automatic welding technology is also adopted in the production of oil tanks. The company's factory building is relatively new, and its management is standardized, which can implement the "5S" standard well. The factory has advanced equipment and standard workflow, and some products can be produced by assembly line.
The company was established in February 2002, 65438. It is jointly funded by Taiwan Province Liuhe Machinery Co., Ltd., Guangxi Fangsheng Industrial Co., Ltd. and Taiwan Province Jiji Machinery Co., Ltd., with a total of 485 employees. The company is currently operating in good condition. In 2008, the product sales revenue was 203.53 million. It is estimated that in 2009, the sales revenue will be 250 million yuan and the profit and tax will be 30 million yuan. The company has advanced production equipment, adopts advanced CAD/CAM system to design and manufacture molds, has the production capacity and testing capacity of stamping, metal cutting, welding and painting, and has the strength to independently design and develop auto parts.
The company's main products include automobile parts assembly (including passenger car body sheet metal parts, front/rear suspension and swing arm suspension), automobile container assembly (including power steering fuel tank, fuel tank and gas cylinder) and so on. Liuzhou Liuhe Fangsheng Machinery Co., Ltd. passed the ISO900 1:2000: 2000 and QS-9000: 1998 standard quality management system certification in 2003, and passed the ISO/TS 16949: 2002 standard quality management system certification in 2006, and won the national certification in the same year.
However, due to the large number of us, it will bring inconvenience to production, so we can only walk around the factory under the leadership of the staff. Many details were not carefully observed, and many things worth learning were not carefully understood, which left a little regret for our internship.