Towards intelligent manufacturing, Jiangsu Yidong Airlines creates a new model of transformation and development
At present, the popularity of intelligent manufacturing is high, and industries such as automobile manufacturing, aerospace, aircraft manufacturing, steel, petrochemical, and mechanical equipment manufacturing have begun to explore smart factories. Jiangsu Yidong Aviation Machinery Co., Ltd. realizes the transformation and improvement of manufacturing through "intelligent manufacturing", uses automation technology and intelligent technology to establish differentiated competitive advantages, improves production efficiency and product quality, responds quickly to market changes, and achieves feasibility in fierce competition. Sustained development.
Jiangsu Yidong Aviation Machinery Co., Ltd. (hereinafter referred to as "Yidong Aviation") was established in December 2010, dedicated to the research and development of various aero-engine motors, automobile motors, motorcycle starter motors, electric motorcycle motors, and new energy vehicle motors , production and sales.
The company implements the enterprise spirit of "taking the essence of Honda and building the spirit of Yidong", implements the ISO/TS16949 quality management standard, and through scientific management and the joint efforts of all employees, relying on the company's advanced and complete testing and testing facilities, product quality has won With the trust of customers, it has become a strategic partner of Honda of Japan, Piaggio of Italy, and TVS of India, and a global procurement supplier of Honda. The automobile motor cooperates with Chongqing Hydes Group. The motorcycle starter motor is the main supporting unit of Wuyang-Honda Motor (Guangzhou) Co., Ltd. and Xindazhou-Honda Motor Co., Ltd. It also cooperates with Qingqi Suzuki, Linhai Yamaha, Taiwan Sanyang and other well-known The brand has established a good cooperative relationship, and some products have been exported to Japan, Thailand, Vietnam, Malaysia, Italy, India, Brazil, the Philippines, France and other foreign markets.
In the era of the Industrial Internet, the manufacturing industry faces more intense market competition. The car window motor is a product with fierce market competition. It has high technical requirements and high labor intensity. The original manual production method is no longer suitable for the current market competition requirements. It is urgent to improve and introduce intelligent technology for transformation. It is an inevitable choice for the development of the industry, and it is also the current direction of Yidong Airlines.
Smart manufacturing is on the way
machining automationThe advanced auto motor rotor/complete machine integrated automatic assembly line, combined with the double-speed chain conveying, perfectly combines the motor rotor, the motor stator and the motor assembly assembly, making the production site more regular and reducing the workload of workers.
Intelligent quality inspection
The workshop production line adopts intelligent quality testing equipment in all key processes, which realizes online automatic testing, automatic recording and alarming. Specifically, the shaft end runout detection is carried out by the shaft-entry iron core automatic equipment; the shaft runout detection is carried out by the automatic shaft jumping equipment; Balance testing and sorting of non-conforming products.
Product information traceable
Batch management of raw and auxiliary materials, and the information of raw and auxiliary materials, production time, production line, operation shift, customer information, product characteristics and other information are summarized through QR code to form a complete processing information flow of products. The dimensional code can trace the entire production process information of products, including raw and auxiliary materials, and connect with the ERP system.
1. The production cycle is reduced from 14 seconds to 8 seconds, and the production efficiency is increased by 42.8%.
2. Reduce the number of workers by 114, increase the utilization rate of energy resources by more than 25%, and greatly reduce the manpower and material resources put into production.
3. Through the process quality inspection, the product quality has been improved by more than 3%, the production stability has been improved, and the product quality has been improved.
4. All manual processes with safety risks are protected by gratings to achieve safe production.
Internal and external training
Multi-pronged approach to make up for shortcomings
The production workshop of Yidong Airlines belongs to the discrete manufacturing mode. The construction of the intelligent workshop is mainly to realize the integrated optimization of enterprise design, process, manufacturing, management, logistics and other links through continuous improvement, and to promote the digital design of the enterprise, the intelligent upgrade of equipment, and the optimization of technological processes. , Lean production, visual management, quality control and traceability, intelligent logistics and other aspects of rapid improvement.
In the future, a digital model has been established for the overall design, technological process and layout of the smart workshop of Yidong Airlines, and simulation is carried out to realize the digital management of the whole process of planning, production and operation.
In the future, the intelligent workshop of Yidong Airlines will use digital 3D design and process technology for product, process design and simulation, and verify and optimize through physical inspection and testing. Establish product data management system (PDM) to realize integrated management of product data.
In the future, the intelligent workshop of Yidong Airlines will realize the interconnection and high integration of key technical equipment such as high-end CNC machine tools and industrial robots, intelligent sensing and control equipment, intelligent testing and assembly equipment, intelligent logistics and warehousing equipment in production management and control.
In the future, Yidong Airlines' intelligent workshop will establish an automatic production process data collection and analysis system to fully collect production site data such as production progress, product information, on-site operation, quality inspection, equipment status, and material transfer, and realize visual management.
In the future, the Manufacturing Execution System (MES) of Yidong Aviation Intelligent Workshop can cover more functional modules and realize the whole-process closed-loop management of planning, scheduling, quality, equipment, production and energy efficiency. The enterprise resource planning system (ERP) is interconnected with MES, WMS, PLM and other systems to realize the optimization of enterprise operation and management such as supply chain, logistics, and cost.
In the future, the intelligent workshop of Yidong Airlines will establish an interconnection network structure within the workshop to realize the design, process, manufacturing, inspection, logistics and other manufacturing process links, as well as with the manufacturing execution system (MES) and enterprise resource planning system (ERP). Efficient collaboration and integration to establish a unified platform for product information throughout the life cycle.
In the future, the intelligent workshop of Yidong Airlines will have an industrial information security management system and a technical protection system, and will have information security assurance capabilities such as network protection and emergency response. A functional safety protection system is built, and a full life cycle method is adopted to effectively avoid system failure.
Blueprint Planning of Yidong Airlines Intelligent Workshop
General description of the automation solution
First of all, the construction of the intelligent workshop of Yidong Airlines should strengthen the transformation and upgrading of the workshop in terms of automation, and realize the automation of the entire workshop production by transforming the existing production equipment or introducing new equipment. In the future, the automation transformation and upgrading of Yidong Airlines can be considered from the following aspects:
1. The flow automation between production materials
The material flow between the various processes and the flow of the entire material system in the workshop can adopt the mode of conveyor belt or AGV, which is conducive to improving the beat efficiency of each production process and paving the way for the realization of production automation in this workshop in the future.
2. Automated three-dimensional warehouse
Sort out the types of products, the number of products placed on each pendant, etc., classify and sort out the mass-produced products, and use the robot to realize automatic feeding.
3. Implementation of intelligent warehousing system
Establish and implement an intelligent warehouse management system to strengthen the in-out, automated distribution and scientific management of workshop materials, work-in-process and finished products.
General description of the informatization program
In the future, the digital workshop of Yidong Airlines will be built into a digital model for the overall design, technological process and layout of the workshop/factory, and simulation is carried out to realize the digital management of the whole process of planning, production and operation; three-dimensional CAD, CAPP, design and Advanced technologies such as process route simulation and reliability evaluation; product information can run through design, manufacturing, quality, logistics and other links to achieve product PLM; a production process SCADA system has been established, which can fully collect production site information and implement it with workshop manufacturing The system realizes data integration and analysis; establishes workshop MES, realizes closed-loop management of the whole process, and integrates with ERP system; establishes workshop-level industrial communication network. Using cloud computing, big data and other new generation information technologies, on the premise of ensuring information security, intelligent optimization of operation, management and decision-making can be realized.
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