The "13th Five-Year Plan" period is a critical period for my country's manufacturing industry to improve quality and efficiency and become stronger. Intelligent transformation is the key to building a manufacturing power. Realizing "digital and intelligent" manufacturing is a new trend in the development of manufacturing industry and the core of a new round of scientific and technological revolution and industrial transformation. At present, China's intelligent manufacturing industry is still in the initial stage of development, and most enterprises are in the initial stage. Taking the electronics industry as an example, Foxconn, an EMS company, has gradually accelerated the pace of "machine substitution" in 2015, and home appliance manufacturers such as Hisense and Gree have also made great efforts in automated production lines. Such as this, the intelligent manufacturing of most enterprises is still in the primary stage, but the cost benefits are obvious.

At present, domestic manufacturing enterprises are promoting the construction of intelligent manufacturing in full swing, and enterprises are gradually beginning to try to promote relevant applications in the seven aspects of "intelligent R & D", "intelligent logistics", "intelligent production", "intelligent management", "intelligent service", "intelligent product" and "intelligent equipment". Some enterprises pay attention to "transformation and upgrading", while others pay attention to "improving quality and efficiency".

 

According to the official website of the Bureau of Statistics, in 2016, industrial enterprises above designated size across the country achieved a total profit of 6880.32 billion billion yuan, an increase of 8.5 percent over the previous year. From January to April 2017, the total profits of industrial enterprises above designated size increased by 24.4 year-on-year, and the growth rate slowed by 3.9 percentage points from January to March; among them, the profit increased by 14% in April. The slowdown in industrial profit growth is a reasonable return after the previous high growth. Overall, the current industrial profits are still maintaining a good growth trend. This should also be the application effect of most enterprises currently promoting intelligent manufacturing. It also gives confidence to enterprises that are currently on the sidelines or waiting.

The purpose of manufacturing enterprises to promote "improving quality and efficiency" is to effectively control various costs, improve production efficiency, improve technology, quality and service levels, innovate development space, and enhance market competitiveness. To this end, manufacturing companies should establish relevant promotion teams and mechanisms to guide various departments of the company to reduce costs and increase efficiency, innovate production and operation models to increase efficiency, market development to increase efficiency, strategic transformation to increase efficiency, manage and control production and operation costs, and actively extend Industrial chain, expand new space for development, change production and operation models, accelerate entrepreneurial innovation, improve strategic adaptability and risk prevention and control capabilities, and promote and ensure the quality and efficiency of enterprises. Combined with its own actual situation, identify the shortcomings and bottlenecks that restrict the improvement of quality and efficiency, actively benchmark with domestic and foreign enterprises, clarify the gap and promotion direction, formulate targeted main paths for breakthroughs, and effectively improve the quality of development, Increase benefits. However, to be clear, the path planning must be clear, do not be greedy for perfection, but to be broken one by one and implemented step by step. It should be clear to everyone that the six elements of the production process (human, machine, material, method, environment, measurement)) and the six objectives (efficiency, quality, cost, delivery date, rustic, reliability) are the focus of management work, and the improvement of quality and efficiency is still promoted around the six elements and six objectives.

1. Quality improvement

The influencing factors of product quality run through the whole life cycle of the product, and the quality information of the whole product cycle from research and development, procurement, manufacturing, quality assurance, sales and customer service must be collected, monitored and analyzed. Manufacturing enterprises must establish an effective quality data collection mechanism, collect quality-related information in the six elements of the whole process, ensure the timeliness and accuracy of quality data to a large extent, and build a product quality data center. What is more important is to make good use of the data of the product quality data center and tap the value of it. It is not only to make a simple analysis, but to find problems through analysis, then formulate supervision and improvement measures, and organize the implementation. Next, we will enter a new round of PDCA cycle: quality data collection-data analysis-discovery of problems-formulation of improvement measures, organization and implementation, and so on. In the cycle, enterprises continue to strengthen the supervision and management of quality problems, and effectively achieve the continuous improvement of product quality.

From the beginning of product development and design, to the entire production process and even put into use in the market, a complete product digital file can not only ensure the integrity of product data, but also realize the integration of design and manufacturing on this basis, and realize the prevention-oriented manufacturing process. A quality control system supplemented by monitoring and analysis and improvement as an effective means.

In addition, do not let the existing quality engineering and management system of the enterprise become a document on the document server, but to become a guiding document to guide the enterprise to improve product quality, so as to realize the functional transformation of quality personnel from "after-the-fact remedy" to "prevention in advance", so as to enhance the core competitiveness of the enterprise itself.

2. Increased efficiency

In the production process to improve production efficiency, still from the six elements to analyze the problems in the production process:

People: employees have low working skills (employee skill assessment mechanism lags behind) and lack of effective skill training; The team leader has insufficient management ability, fails to apply according to materials, and lacks supervision function. Lack of reasonable incentive mechanism, low enthusiasm for team work, low morale, lack of responsibility and weak sense of efficiency.

Machine: The production equipment and clamping fixtures lack standardized maintenance and maintenance requirements, no special person is responsible for management, basic information such as ledgers, status, use records, routine inspection and maintenance records, and maintenance records are missing, and some equipment and clamping fixtures lack operation guidelines, resulting in improper operation of employees and seriously affecting production efficiency.

Materials: no clear and feasible management system has been established for material procurement, storage, transportation, quality inspection, etc. No batch or sequence management has been carried out on purchased raw materials, semi-finished products and finished products. No effective control method has been established for suspicious and unqualified products in the process. Material information collection in the production process relies on paper documents, which is inefficient and not conducive to material traceability.

Method: The production process design and operation methods of some products are unreasonable, resulting in discontinuous production process and low efficiency. SOP lacks practicability and the operation method of employees is not standardized. New products and products that have not been produced for a long time lack engineering and technical guidance, with many abnormalities, untimely processing and rework consuming a lot of working hours. The production arrangement and wiring are unreasonable, the balance loss is large, and the waiting waste is large.

Ring: chaotic production site planning, backward 5S management, no fixed management of materials and tools, and lack of visual visualization on site, resulting in waste of time for employees to find and take materials and tools.

Measurement: In view of the low standardization of inspection specifications, a large number of manual fill-in content. The test report needs to be manually sorted out. Whether it is self-inspection, mutual inspection or special inspection, it is only recorded according to the standard and does not play the true value of inspection.

These six aspects of efficiency improvement, some need to improve management, some need to introduce information systems to cooperate with management to improve efficiency, and some need to carry out lean production planning and improvement.

3. Cost reduction

I believe that many enterprises have promoted the budget, strategic cost concept, target cost management, strengthen cost accounting, the establishment of cost responsibility system and other perfect cost management and control system, but, from a technical point of view to solve the problem of higher costs, but also need to find a cost increase point that can be optimized.

The cost source of a manufacturing enterprise is the sum of the various expenses incurred in the manufacture of a certain type of product and quantity, the cost factor runs through the whole life cycle of the manufacturing activity, and the production cost is divided into direct costs (raw material costs, workers' wages, etc.) and indirect costs (management costs, depreciation costs, maintenance costs, machine material consumption costs, etc.). In addition, there is a quality cost, which is a cost structure that can be actually data and analyzed.

Direct costs, regular through product design improvements and production process improvements, reduce consumption quotas to reduce costs.

Indirect costs, the regular is to strengthen the budget management of expenses, improve the cost control granularity of each unit to reduce costs.

Quality cost, regular from the product raw materials, process, process three aspects to strictly control to reduce the poor quality cost.

For manufacturing enterprises, whether it is process improvement, machine replacement, or improving control granularity, it is an important topic, such:

In foundry enterprises, melting link, through the transformation of equipment, improve the combustion utilization rate of gas, reduce consumption quota.

In the equipment control link, through equipment status data collection and big data analysis, optimize the frequency of equipment maintenance and the service life of spare parts, reduce costs.

For the wages of employees, the analysis of low-tech content, high frequency of operation can use machines to replace people's jobs, optimize the structure of personnel, improve the efficiency and accuracy of operations, thereby reducing costs.

Enterprises that use piece-rate wages should monitor the rationality of the plan, the authenticity and timeliness of piece-rate reporting data, and calculate costs with excellent tasks and accurate data.

In the spray shop, optimize the spray plan and delivery plan to reduce the cost with low paint waste and manpower waste.

Taking relay production as an example, the traditional manual operation is replaced by one-time automatic assembly, testing and packaging equipment, and the "unmanned chemical plant" is initially established to cope with the increasing labor cost in China;

Through equipment data collection and quality data analysis and other means, real-time monitoring of product production process parameters, reduce the production of defective products.

Reduce labor and time costs in the production business process through digital management of the production process.

The essence of intelligent manufacturing is to organically connect intelligent equipment (including but not limited to robots, numerical control machine tools, automation integrated equipment, 3D printing, etc.) through communication technology to realize automation of production process, optimize production process and improve production efficiency; and collect various data in the production process through various sensing technologies (sensors, RFID, machine vision, etc.) and upload them to industrial servers through communication means such as industrial Ethernet, under the management of MES software system, data processing analysis is carried out, and it is connected with enterprise resource management software (ERP) to provide optimized production plan or customized production to realize intelligent production. Research and develop innovative intelligent products to create new business models and establish new business value growth points for enterprises in the new market environment. Let the path of improving quality and efficiency be clearer, the implementation be more transparent, the decision-making be more scientific, and the effect be more obvious.