In the era of Industry 4.0, smart factories have become very popular. Fast, a leading company in the drivetrain industry for commercial vehicles, and Fastest manufacturing experts, rely on scientific and technological progress and independent innovation to closely track global advanced technologies and continuously accelerate the pace of production automation and intelligent development. Unique "smart manufacturing" approach. Lean production, the "foundation stone" of intelligent manufacturing Lean is listed by Germany as one of the four modules that constitute the future smart factory. Lean production is also the basis and guarantee for Chinese companies to implement Industry 4.0 and accelerate the transformation and upgrading. As early as 2009, Fast Company formally initiated the "Scientific Improvement, Increased Efficiency, and Reduced Cost (KTJ)" campaign to fully implement lean production. The fluency of processes in the lean production method is the basis for optimization of the production line. Fast demanded that "one stream" be used to lay out production. In the initial stage of implementation, six production lines, including the 12th Assembly Line of the fifth workshop, the intermediate shaft of the third workshop of the toothed joint, 1124, the sliding sleeve, the main shaft of the auxiliary box, and the second shaft, were leanly transformed and succeeded. The transformation of these production lines through the implementation of "a stream of production", the production line by a single-step transfer between the slides, no carts, a part from the incoming line to the line of the processing cycle significantly shortened. The number of handling operations has been greatly reduced, and the logistics in the line has been smooth. This not only reduces collisions, but also promptly discovers problems and reduces the probability of batch quality accidents. Through large-scale lean transformation, the production efficiency has been greatly improved, manpower resources have been saved, work-in-process has been reduced, and the per capita efficiency has increased by more than 30%, laying a solid foundation for automated production. Lean logistics, smart manufacturing "conveyor belt" In 2012, Fast started the “Lean Logistics†project and upgraded the implementation of lean logistics to the strategic development level of the company. First, the 6DS comprehensive warehouse in Baoji Plant was used as the pilot for lean logistics, and the implementation of lean logistics was carried out in a way of “establishing pilots and gradually advancingâ€. The implementation was then extended to the entire company and the Fast Logistics System was fully promoted. In other words, the FLS) construction will further enhance the company's business philosophy and form the Fast Operation System (FOS). Integrate the layout, production line layout, production and logistics modes of the new plant with the Lean concept. Through the brand-new design of the logistics method in the workshop, the process is smooth and the labor intensity of the workers is reduced, the rough blank management, the first-in, first-out are achieved, the scattered sites are integrated, the utilization rate of the production space is increased, the visual degree of the site is improved, and the management is convenient and reduces. A lot of handling, to avoid the unnecessary waste caused by the long distance and logistics information in the post-production process. Warehouse Management Informationization, Smart Manufacturing "Good Housekeeper" While implementing lean production and lean logistics, the pilot work of the procurement warehousing information management system also began. The warehouse IT management system covers major functions such as electronic reception, electronic distribution, real-time material inquiries and on-line settlement. It achieves the sharing of material storage information between different legal entities and different use units, and achieves the purpose of avoiding repeated purchases and reducing the use of acquisition funds. . Since the official operation of the purchasing warehouse information management system, it is more intuitive and simple than the original ERP system operation. It consists of seven modules: system maintenance, basic data management, auxiliary materials management, spare parts management, tool management, VMI management, and comprehensive statistical analysis. It has greatly facilitated the procurement of warehousing. During the use of the system, the procurement warehousing and statistical reports are clear and clear. It is very convenient to increase or decrease the quantity of materials, and it is very convenient for on-line settlement. With the VMI supplier management system, the supplier can understand the inventory of the supplied materials in real time. Situation and on-line settlement, convenient for reconciliation. Through the sub-library division, it is convenient for the workshop to pick up the required materials nearby, eliminate the phenomenon of misplacement of goods from the source, and the system materials can directly bring out the supplier information to ensure that the purchased funds can be traced back. At the same time, the shop purchase requisition is associated with the purchase order, to ensure the first time to understand whether the purchase of the purchase funds is in storage. The special approval function added in the system saves the examination and approval of the original paper documents, which not only reduces the labor intensity of material personnel, but also strengthens the supervision of the competent department. Automatic assembly of cantilever wire, smart manufacturing "new power" Recently, the “Heavy Card Transmission Automatic Cantilever Assembly Line Project†developed by Fast and the Shenyang Institute of Automation of the Chinese Academy of Sciences has successfully passed acceptance, adding energy to the company’s smart manufacturing. The J-hook Assembly Line combines industrial automation, communications, intelligent robots, tightening and tightening, information control, and testing, and multi-station automation. The assembly line is equipped with functions such as automatic operation, stoppage, rollover, lift, precise positioning and safety protection. The robot realizes functions such as flexible pitch tightening, automatic gluing, transfer line handling, and precision assembly. On-line press-fitting eliminates the risk of quality caused by bearing knocks. The over-the-air logistics system docks the washer and automatically transports the parts to the assembly station, eliminating part collisions. With six degrees of freedom robots, online automatic detection and product flow automatic control are realized, and a variety of product flexible assembly lines can be completed to achieve a single delivery mode. The qualification rate for one-time packing is increased by 3%, the production capacity of assembly line is increased by 25%, the floor space is saved by 27%, labor intensity of workers is effectively reduced, and product assembly automation and intelligence are greatly improved.
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