With the wave of industrial 4.0, improving efficiency, ensuring quality and reducing costs have become the key for enterprises to win in the fierce market competition. So, how do you practice your internal skills and achieve your own transformation and upgrading? A subsidiary of Shougang Group gave a vivid case-by selecting excellent partners, optimizing the processing process, and building a system platform, it successfully achieved a perfect transformation, exuding vitality and vitality in the new era.

The subsidiary enterprise located in Qinhuangdao was founded in 1970 and is a typical old-brand machining enterprise. In recent years, through the reform of state-owned enterprises and the transformation of the shareholding system, the enterprise has gained vitality in the system and mechanism, and has opened up a new market in the integration of the army and the people. As a major machining enterprise within Shougang Group, after years of development, the company has strong competitiveness in the industry: dominated by large and medium-sized products, occupying 30% of the national market share; metallurgical accessories supply more than 30 enterprises in China, and are exported to Europe, America and Southeast Asia. Although the comprehensive ability occupies a leading position in the same industry, the factory also has two great bottlenecks in actual processing-efficiency and quality.

How can we keep up with the pace of the times and keep ahead? It is an inevitable choice to rise to the challenge and overcome the bottleneck. However, this is not easy: due to its long history, the production process of the factory has been followed for 2. 30 years. The processing equipment is mainly domestic machine tools and the types are complicated. It has only been a few years since the addition of CNC machine tools, and the processing speed has been limited; It produces as many as 17 kinds of parts and components, which consumes a large number of tools every year and requires huge manual force. In addition, affected by the specific conditions of the metallurgical industry, its products are relatively extensive, poor accuracy. "The metallurgical industry was originally extensive, and the requirements for product quality were not particularly high, but in recent years the industry has also been moving in the direction of'high-precision and sharp'; with the continuous increase in orders, although we added some A few years ago Advanced processing equipment, but the use and management of tools is not fine enough, which greatly affects our quality and efficiency." The person in charge of the plant always recalled with emotion, "The market competition is becoming more and more fierce, labor costs are rising continuously, customer demand is becoming more and more diversified and refined, and improving efficiency has become the key. We urgently need to make a change in production and processing!"

At this critical moment, the factory began to join hands with an important partner to jointly start this major change that will win the future-this partner is the world's well-known tool manufacturer, Shangao Tool.

"At the beginning, we faced many problems, but after we started to cooperate with Shangao, these processing problems were easily solved." Recalling the difficulties faced at that time, the person in charge said humorously, "through the cooperation with Shangao, our process has been greatly optimized and the transformation from extensive to fine has been realized. The processing quality is more stable and the production cost is greatly reduced. The most important thing is that our production efficiency has been greatly improved, and the delivery cycle problem of batch processing has been solved in one go."

So, how did this huge change come about?

It turned out that the factory built the whole tool platform through close cooperation with Shangao. Taking the tool platform as the starting point, the process adjustment and processing beat point combing were made for each part, and the whole process was solidified and standardized, thus realizing the transformation from "extensive" to "fine. In this process, mountain high with rich experience, put forward many suggestions for process optimization and tool selection and finally realized one by one, thus laying a solid foundation for the transformation; and with the optimization and improvement of the process and the reasonable choice of tools, not only the product quality has been steadily improved, the production efficiency has been greatly improved, but also the number of unnecessary personnel has been reduced and the labor cost has been reduced.

Before cooperating with Shangao, the factory had a CNC finishing workshop that selected many brands of tools, but because they were selected based on experience, the variety of tools was complicated and the processing effect was uneven, resulting in great waste. To this end, after carefully screening the company's processing process, in order to improve efficiency and stable quality and other practical results as the starting point, together with the dealer Rixin Zhuoyuan Company, set up a tool optimization team, put forward new ideas for improvement. "During that time, the mountain high is in our processing site office, on-site observation to develop programs; product development after the completion of the trial, after the trial and then feedback, feedback and then constantly improve and adjust. It is through such tireless efforts, do our best to pay, we finally achieve the optimization of the process, efficiency improvement." The person in charge said. Bi Jinghao, who is the technical director of Sago focusing on this project, also recalled with emotion: "This is an extremely typical customized application, and there are no foreign cases to refer to. Thanks to our team's excellent solution capabilities, but also because of the tacit cooperation of the three parties, it is very rare in the industry to achieve the expected goals so quickly and as a whole." Hard work and close cooperation eventually produced many results. Taking the internal thread processing of workpieces as an example, the original process of the factory uses taps on tapping machines. This process has many defects: first, taps are easy to break, cannot tap suitable threads, and the accuracy is difficult to meet customer requirements; Secondly, taps have short service life and high cost. In order to process suitable products, it is often necessary to purchase a large number of taps, but in the end it costs nearly 100 taps, the quality of processed products cannot be fully guaranteed. "This problem has plagued us for many years, let us very headache. High cost, good rate is 90%.".

In response to this difficult problem, Shangao and the staff of the factory worked together to creatively propose a way to replace taps by car processing-by using Shangao's new Mini-shift slot cutter and matching threaded blades, they are directly processed on the lathe. The results are shocking: the original processing time was 4.8 minutes, but now it only takes 17.4 seconds, the production efficiency has been greatly improved by 94%, and the yield rate has reached more than 99%! In addition, the improved process also reduces the number of production personnel to 1-2 people, while reducing one card loading and two turnover, resulting in a reduction in costs. The problems that have plagued enterprises for many years have been solved.

Another example worth mentioning is the optimization of workpiece process merging-the optimized process merges the traditional two processes into one piece by using a high cutting knife, and the finish requirement can be met directly with one knife, thus reducing the processing time from 12.6 minutes to 3.9 minutes and greatly increasing the efficiency by 68%. However, in the processing of workpieces with complex shapes, many inner cavities and many grooves, due to the technical support of Shangao, the improved process can directly replace the original 32 processes, and the processing can be completed in only 4 times, reducing the original operation of more than a dozen people to 6. seven people. Through the use of mountain high Steadyline seismic knife, processing a deep hole cavity shaped products, the core workpiece processed by the factory to fill the national gap.

Many such examples have gathered and finally produced exciting results-if the cost is calculated by thousands of pieces, the processing cost after process improvement is only about 1/3 of the original cost. Excellent efficiency improvement and time saving have greatly enhanced the competitiveness of enterprises, and labor costs have been reduced by 20% compared with the original. In addition, invisible consumption such as water and electricity has also been reduced, reaching an immeasurable level. Today, the factory has been fully equipped with mountain high on the turning tool, using the latest DUROTOMIC products of mountain high. To some extent, it can be said that it is through close cooperation with Shangao that the "internal skill training" of the factory has been greatly enhanced, from the "old man" with old craftsmanship and slow pace in the past to a "youth" with advanced craftsmanship, high efficiency and abundant physical strength, showing a vigorous and vigorous fighting spirit in an era of increasingly fierce competition.

Now recalling this major change in production, the person in charge sighed with emotion: "Through close cooperation with Shangao, we have achieved tool shaping, process shaping, and production rhythm shaping. From the extensive processing in the past, we have gradually moved to semi-automation, and then to full automation, and the innovation ability and production efficiency have been maximized. It can be said that among the peers I have contacted, Shangao's service is the best and the best. We carefully inspect our production line almost every day, and we try our best to meet any requirements we put forward. They have given us great support and are very touching."

In 2017, the plant will also add more than 20 pilot projects and set foot in the aerospace sector. A new production line is being actively planned to further expand capacity. Their goal is to further improve the level of refinement, improve production efficiency; at the same time, promote the quota management of tools, and continuously reduce costs. Li Zhongliang, head of sales for this project, said: "The factory has entered the fast track of development. Its leaders and employees have a high acceptance of innovation, which has enabled Shangao to give full play to its advantages. We are willing to continue to contribute to this and believe that Shangao will bring greater value to the competitiveness of this customer."