Recently, the reporter deliberately visited Jiaxibeila Compressor Co., Ltd. (hereinafter referred to as Gacibela) in Jiaxing City, Zhejiang Province. It is reported that the company is a professional refrigerator compressor manufacturer with the first domestic production volume, the second largest volume in the world, and more than 50% of its products for export. In addition, the company is still the company with the highest level of automation in the compressor industry. In their newly formed third factory, many precision parts are produced by robots.
Competing with intelligent robots In the machine shop of Garciabella's third factory, we saw a tall and tidy workshop. There were only a few workers in front of the rows. Instead, some robot arms were working hard. They were tireless. Accurately picking, processing, and assembling a series of precision parts. The entire process is smooth and smooth.
Ding Xiaolin, deputy director of the workshop, told reporters that the compressor is also known as the "heart" of the refrigerator. Although the appearance is not much bigger than football, the technology content is very high. All the highest precision components in the compressor products are produced in the workshop, including more than 400 models of 6 series and 7 large parts.
Do intelligent robots also need quality control? How to control the production quality of intelligent robots?
Ding Xiaolin told such an example.
The machine shop has two best crankcase machining machines in the industry, but there are two small problems that have plagued the workshop technicians. First, after the aging of the belts of the two machine tools, the products will have quality problems; second, the tools After a certain number of jobs, problems will begin to arise. The machine has 12 stations, 30 processing units, that is, 30 spindles and 30 belts. Through the physical monitoring measures such as spindle temperature monitoring, belt vibration detection and equipment maintenance records, they discovered some laws of spindle bearing wear and belt aging, found their life cycle, and then worked out a regular rotation replacement plan. Replacement is planned in the production gap. At present, all critical and key equipments in the workshop have formulated a detailed equipment check system and equipment failure warning plan for major faults. The same is true for the knives. They found that one of the knives started to have a problem when it was around 1,000 products. So when it produced 900 pieces, they alerted them through the monitoring of the equipment program and reminded employees to replace them in time. . Each tool on the shop floor currently has a life cycle and institutionalizes it. Through the implementation of these systems, many quality problems can be eliminated before they happen.
Many people will not think that the detection of parts is sometimes more time-consuming and labor-intensive than production. In the machine shop, it takes only a few seconds for each part to be produced, and it takes nearly 30 minutes to manually detect one. If only manual inspection is used to ensure quality, it will not only waste a lot of manpower and material resources, but will also greatly affect the production efficiency. This requires the Gacibelians to monitor any quality fluctuations in production in time and to eliminate all possible quality problems in the bud.
To this end, they used quality management tools such as SPC, CMK, MSA, QRQC, and information technology.
For example, in manufacturing systems, such as InfinityQS and other application statistical analysis technologies, the production process is monitored in real time, and the random fluctuations and abnormal fluctuations in the product quality during the production process are distinguished, thereby giving an early warning of the abnormal trend in the production process.
Another example is FCS, a fieldbus control system that monitors equipment status and equipment parameters in real time and implements remote monitoring and remote diagnostics.
The radio frequency technology (RFID) runs through the entire assembly process of Gacibela, achieving a full record and inquiry from the material to the assembly process.
“If the number of scraps per day exceeds the number we specify, QRQC will start in time. Our management personnel on the shop floor will have a client on the handset and will receive an alarm immediately. Our corresponding production management and engineering technicians will arrive at the site. Knowing the circumstances of the alarm, taking measures, and tracking five shifts in a row, there are no major problems before workers are given continued attention, Ding Xiaolin said.
It is said that the reason why human beings can evolve into advanced animals depends on the prevention of mistakes. It is related to human beings' good use of tools, but even human beings with high IQs will have some limitations and shortcomings. For example, eyesight alone can not identify some extremely similar parts, and for example, artificially shorten the processing time because of lazy and other reasons. In order to ensure the quality of products, Gacibelians not only compete with intelligent robots, but also take human weaknesses.
Many of the more than 400 parts in the workshop are very similar, and some can only be distinguished through professional testing equipment. To ensure no mistakes, they have adopted a strict batch management system. Each batch of products has a detailed “ “Identity cardsâ€, which model is the incoming raw material, which supplier provides, what the quantity is, who is on which day and which of the equipment, and how much is scrapped, all of which must be made clear. However, some parts are too similar, and it is impossible to mark the parts. In order to prevent human error, they mark different colors on the parts tracking card at a glance to ensure that employees can make fewer mistakes and make no mistakes in production.
In 2010, customers reported that a component of the compressor produced by the company had oil stains that affected the start of the refrigerator. It turned out that at that time, Gacibela had just made a process adjustment. Because the compressor was a sealed whole and the failure occurred only after the compressor had been stored at the customer's place for almost a year, the company did not find the problem in time. After receiving customer feedback, the company and the workshop paid great attention. Through the internal analysis of the compressors, they found the key point of the problem, as long as they burn off those oils in a timely manner, which will not affect the process adjustment, but also ensure the quality of the compressor products. However, customers still have some concerns because the products in the machine tool can be artificially taken out after baking for some time. They feel that if the workers do not do it, they will still have an impact on product quality. How can we ensure that the baking process will not be artificially negligent? The workshop technician simulated the access control system of the cell and made “anti-error measuresâ€. Only when the parts have reached the required process temperature and time, the door of the machine tool can be opened and the parts can be taken out from the machine tool. The problem is solved perfectly.
Ding Xiaolin told reporters that since the establishment of the workshop, similar anti-error technology, they have done more than 40, and many of these ideas are thought of by the frontline staff of Gacibela.
Constant Pursuit of Excellence The pursuit of quality by the Gacibelians is not limited. This is manifested not only in their ability to compete with intelligent robots and in human weaknesses, but also in their daring to challenge themselves and their limits.
There is an important part in the compressor called the crankcase. The crankcase has a two-hole perpendicularity CPK. The CPK can only be about 1.0, which is also the current high level of processing in the industry. Although customers understand the current industry level, they still hope that CPK can achieve 1.33 or more. In order to better meet customer requirements, the engineering and technical personnel of the workshop conducted a comprehensive analysis of the combined data of 120 fixtures affecting the two devices required. After long-term monitoring of more than 20,000 data, they found that theoretically The full-floating fixtures are not truly full-floating, so they broke through the original thinking and decisively optimized and improved the fixtures. As a result, the CPK has been raised to about 1.2. Although the customer's requirements have not been fully met, the customers are in the After the second audit, I was very happy and praised and recognized their efforts.
In the machine shop, the factory audits from customers each year, no less than 100 batches.
In recent years, the company has vigorously advocated the concept of “everybody can create miraclesâ€. Every year, in the machining workshop, a large number of QC teams and mass economic and technological innovations and rationalization proposals are produced. This year, they will also invest 5 million yuan in the automation of 13 projects.
In Ding Xiaolin's opinion, quality itself is continuous improvement, and the driving force for continuous improvement comes not only from the needs of customers, but also from the need to continuously reduce costs.
It is precisely because of this continuous effort that the company not only received orders from more than 30 countries in the world, but also won the first Jiaxing Mayor Quality Award, the Zhejiang Provincial Government Quality Award and the National Quality Award.
At the end of the interview, Ding Xiaolin told reporters that the highest realm of quality management is to predict, find and eliminate quality problems in time, and the key to quality management is people. Only the initiative of every employee is fully mobilized. Only with enthusiasm can we finally manage product quality. "In a word, the key to quality management is the quality management of all employees."
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