(1) Guangxi Liugong Machinery Co., Ltd.

1. The morning of June 5th

We arrived at the gate of Liugong at 9 o'clock in the morning. First, Huang The teacher led us to visit the Liugong Product Exhibition Hall, where he introduced us to Liugong’s products. Whether it is the leading product loader, or other products such as excavators, road rollers, pavers, forklifts, etc., the sales are among the best in the industry. , which reflects LiuGong’s strong technical strength.

Then, Teacher Huang led us on a general tour of all LiuGong’s factories, giving us an overall understanding of LiuGong’s production.

2. June 5, afternoon

In the afternoon, we visited the heat treatment plant and tool factory.

The heat treatment plant has many large heat treatment machines, forming a fully automatic heat treatment production line, which can complete various heat treatment processes, including normalizing, tempering, quenching and tempering, annealing, straightening, carburizing, Nitriding, cleaning and other processes. Each piece of equipment is equipped with safety protection, and safety warnings can be seen everywhere on the walls and notice boards, which reflects LiuGong's emphasis on production safety.

We then visited the tool factory. What impressed me most here was the serious attitude of the workers. A large group of us gathered around the machine tool to watch, but the workers were all focused on the parts they were processing, and they never seemed to notice us around. Same. I believe that the development and growth of Liugong is inseparable from such an admirable group of workers. Here, we took a close look at a variety of machine tools, including traditional and advanced processing equipment such as lathes, milling machines, drill presses, wire cutting machines, and CNC lathes.

3. Morning of June 6th

Visit the gearbox factory in the morning.

We first enter the large parts workshop, where gearbox boxes are produced. The equipment is special machine tools and combined machine tools. Special clamps are used to reduce clamping time and improve production efficiency. Special machine tools are characterized by high processing efficiency but low precision, so combined machine tools with machining centers are used to make up for its shortcomings. For example, on a combined machine tool, the positioning principle of two pins on one side is used, hydraulic clamping is used, and multiple tools on three sides are processed simultaneously. The line micro process of processing the box body is: fine milling of sleeve surface and end cover surface - milling of small pump surface and control surface - drilling and boring - rough boring - semi-finish boring - boring groove - fine boring / Machining center precision boring - drilling one - tapping - drilling two - tapping two - boring, drilling - drilling and tapping - cleaning.

The small parts workshop produces parts such as gearbox gears, pump wheels and spiral bevel gears. In the workshop, there are many machine tools used to process gears, such as hobbing machines, grinders, drilling machines, coordinate boring machines, differential gear milling machines, profiling lathes, broaching machines, slotting machines, machining centers, CNC lathes, ordinary lathes, etc. In addition, many accessories are needed, such as flanges, shafts and other parts. The box factory adopts the advanced enterprise production management concept - U-line theory for production management. This production concept was first proposed by the Japanese and applied to enterprise production practice. The U-shaped line is a production line with multiple varieties and small batches, frequent line insertion and line changes, with the primary goal of reducing the waste of manpower and material resources. The U-shaped production line must place the production input point (Input, that is, the material placement point) and the finished product take-out point (Output) as close as possible. We call this the "IO consistency" principle. That is to say, when the input point and the withdrawal point are close to each other, the time waste of "return" can be avoided. In order to achieve the principle of consistent IO, the production line is arranged in a U-shape like English letters, so it is called a "U-shaped production line". In addition to being used in the layout of production lines, the principle of consistent IO can also be applied to the design of machinery and equipment. The primary purpose is to save manpower, smooth logistics, and eliminate waste. According to Teacher Huang, since the factory adopted the U-shaped line theory for production in 2008, the production cost has been reduced by one-third in half a year, and has achieved good economic benefits.

In addition, on the wall at the entrance of the workshop, we also saw LiuGong’s production management theory, namely Six Sigma (6σ) theory.

Six Sigma was developed by GE in the mid-1990s from a total quality management method into a highly effective enterprise process design, improvement and optimization technology, and provides a series of technologies that are equally applicable to design and production. and new product development tools for services. Then it goes hand in hand with GE's globalization, servitization, e-commerce and other strategies, becoming the most important strategic move for companies in the world that pursue management excellence. Six Sigma has gradually developed into a management philosophy that takes customers as the main body to determine corporate strategic goals and product development and design, and pursues continuous progress.

The 6σ management method is a statistical evaluation method. The core is to pursue zero-defect production, prevent product liability risks, reduce costs, increase productivity and market share, and improve customer satisfaction and loyalty. 6σ management focuses not only on product and service quality, but also on process improvement. "σ" is a Greek letter, used in statistics to represent the standard deviation value, which is used to describe the deviation of individuals in a population from the mean. The measured σ represents such things as unit defects, million defects or errors. Probabilistically, the larger the value of σ, the fewer defects or errors. 6σ is a goal. This quality level means that 99.99966 of all processes and results are defect-free. That is to say, if you do 1 million things, only 3.4 of them will be defective. This is almost as close as human beings can The most perfect state reached. 6σ management focuses on processes, especially the core processes by which companies provide value to the market and customers. Because process capability is measured by σ, the greater σ, the smaller the fluctuation of the process, and the stronger the ability of the process to meet customer requirements with the lowest cost loss and the shortest time period. The 6σ theory believes that most enterprises operate between 3σ and 4σ, which means that the number of operational errors per million operations is between 6210 and 66800. These defects require operators to make up for or correct them afterwards with funds ranging from 15 to 30% of sales. , and if 6σ is achieved, the funds to make up for it afterwards will be reduced to about 5% of sales.

In order to achieve 6σ, we must first formulate standards, track the deviations between assessment operations and standards at any time during management, and continuously improve to eventually reach 6σ. A set of simple process models has been formed to continuously improve each link: define, measure, analyze, improve, and control. It is reported that Liugong has achieved very good economic benefits after adopting this theory.

4. June 6, afternoon

In the afternoon we visited the drive axle factory. The functional characteristics of the transaxle are carrying, driving, differential and braking. Here we come into contact with the so-called "5S" standard. "5S" is the abbreviation of the five words Seiri, Seiton, Seiso, Seiketsu and Shitsuke. Because the first letter of the Roman pinyin of these five words in Japanese is "S", they are called "5S" for short. The "5S" activity originated in Japan and is widely promoted among Japanese companies. It is equivalent to the civilized production activities carried out by Chinese companies. The object of "5S" activities is the "environment" of the site. It comprehensively considers the overall environment of the production site and formulates practical plans and measures to achieve standardized management. The core and essence of the "5S" activities is self-cultivation. Without corresponding improvements in the self-cultivation of the workforce, the "5S" activities will be difficult to carry out and persist. "5S" has become the basis of quality management according to Toyota's management content. Quality management should be based on "5S" management.

May. June 7th, morning

In the morning we visited the foundry. What impressed me most was the pungent smell permeating the factory. The production line here also conforms to the U-shaped line theory and is very efficient. In a casting scrap record sheet in the molding workshop, the main cause of defects is recorded as: "sand inclusion (9 times); pores (1 time)". From this, it can be inferred that in the actual casting production of the factory, castings were The main cause of defects is sand inclusion. Special attention should be paid to this problem during product design, process planning and worker production operations in order to reduce the scrap rate.

Next, we visited the structural parts factory.

Most of the workers here are doing welding operations. On the wall display board of the welding workshop, common welding defects in the welding process are recorded, such as: spark splash, burn through, incomplete slag removal, welding nodules, spark misalignment, and weld seams. It is uneven, has pores, etc., and there are some corresponding prevention and control measures. The processing equipment here includes TCBAR column mobile horizontal machining center, plasma wire cutting machine, shearing machine, forging machine tool, CNC plasma cutting nibbling machine, CNC flame cutting machine and other large advanced equipment. It can be seen that the production mode of structural parts is to cut the plates first and then weld them.

Afternoon of June 7th

In the afternoon we came to another factory of Liugong.

First I went to the hydraulic parts factory. The piston rod is produced by friction welding. Here we observe the entire friction welding process up close for the first time: one part is clamped and fixed, the other part rotates at high speed driven by the spindle, and the two parts face each other. The heat generated by friction quickly melts the contact surface. After a period of time, the rotating parts quickly stop, and then the weld is wrapped with asbestos cloth to keep it warm for a period of time.

Next, we entered the piston rod surface treatment workshop. Here we mainly complete the chromium plating on the surface of the piston rod. The process flow is: fine grinding of the outer circle - inspection - polishing before plating - chromium plating - chromium plating completion inspection - polishing after plating - inspection. Chrome plating adopts electroplating method, and there is an electroplating tank in the workshop.

After leaving the hydraulic parts factory, we went to the thin plate parts factory. The main processes of the thin plate parts factory are scribing, cutting, deburring, forging, welding, painting, etc. For some thin plate parts, the process from steel plate to parts is basically completed here, such as the shell of a loader. The factory has a high-tech diaphragm spray painting equipment production line. From installation and hanging, transfer, spray painting and drying, it is all completed on one assembly line.

(2)Gaohua Machinery Co., Ltd.

On the morning of July 11th

In the morning we came to Gaohua Machinery Co., Ltd. located in Liudong New District, here The scale is much smaller than that of Liugong, and the production process of products is almost all carried out in one factory. Here we mainly design and manufacture automotive stamping dies,

fixtures, inspection tools and produce automotive parts.

Due to the power outage today, Gaohua Machinery Co., Ltd. can only use its own power supply. Due to insufficient power, it cannot carry out large-scale production activities. The reception staff mainly explains the company's situation to us. The company has important departments such as operations department, technology department, quality department, mold department, parts department, and finance department.

The technical department is mainly responsible for the design of automotive stamping dies, fixtures, inspection tools and other tooling, and the formulation of various process documents and work standards. Using AutoCAD, UG, AutoForm, etc. as development work platforms, we have established a complete set of design specifications for molds, clamps, and inspection tools. Ensure that the unit has strong market competitiveness in terms of technology and development management.

The Quality Department is mainly responsible for the quality management of automotive stamping dies, fixtures, inspection tools and automotive parts. We have established a complete set of quality management procedures and standards for molds, clamps, inspection tools and auto parts. The mold department is mainly responsible for the manufacturing of molds, clamps, inspection tools and other tooling. It is equipped with processing equipment such as CNC milling machines, ordinary milling machines, grinders, and drilling machines, mold debugging equipment such as a 600-ton hydraulic press, and measuring equipment such as three-coordinate measuring machines. It not only provides a strong guarantee for the unit's development of auto parts, but also provides the market with design and manufacturing services for automotive stamping dies, fixtures, and inspection tools.

The Parts Department is mainly responsible for the stamping and welding production of automobile parts. The main equipment includes stamping equipment such as 630-ton hydraulic press, 500-ton hydraulic press, 315-ton hydraulic press, punch press, and welding equipment such as vertical spot welding machine, suspended spot welding machine, and oxygen dioxide shielded welding machine.

The company has 336 employees, including 45 engineering technicians, 82 fitters in the mold department, and 173 people in the parts department.

The models involved in the development include Nissan X11M project, Toyota 930L project, Suzuki YP6 project, Wuhan Shenlong Company T33 sedan project, X7 sedan project, T73 sedan project, SAIC-GM-Wuling SPARK mini-car, Wuling Zhiguang series mini-car, Wuling Hongtu, N300 microcars, CN100, N109, N300L, Dongfeng Liuzhou Fengxing Jingyi sedan, Fengxing commercial vehicles, trucks, etc. are suppliers of molds, inspection tools, fixtures and parts for SAIC-GM-Wuling.

Since its establishment, Gaohua has been adhering to the business philosophy of "exquisite life, high-quality Gaohua, and sincere society" and implemented the business policy of "cultivating talents, excellent technology, perfect quality, and win-win market", and has passed International quality system ISO/TS16949 certification.

We also found that although this company is a relatively young medium-sized private enterprise, its factory management is relatively standardized. Because the factory is relatively new, the working environment is relatively good. Moreover, the factory's work pace is not fast and the welfare benefits are good. It provides food, accommodation, and hardware, so it has attracted a group of talents to join. During the visit, we also found that there were employees from Japan working there.

According to company employees, their factory management adopts the "6S" standard, that is, in the "5S" of sorting (Seiri), rectifying (Seiton), sweeping (Seiso), cleaning (Seiketsu) and literacy ( On the basis of Shitsuke, safety in production has been added. This reflects the innovation of my country's private enterprises in corporate management methods and concepts.

(3) Liuzhou Huaqing Engineering Machinery Company

August. June 11 afternoon

In the afternoon we came to Liuzhou Huaqing Engineering Machinery Company, which is a private Enterprise, the company is small in scale. It is a special enterprise engaged in the production of loaders, excavators, graders, and other ancillary equipment, various agricultural machinery manufacturing, and album manufacturing. It also undertakes various outsourced material processing and production. According to an old employee who has worked for the company for six years, the company is contracted to individuals. There are 5 factories in the country, but only one is currently in use. There are less than 20 employees in this factory, and 8 hours The work system is based on piece-rate production. Due to the poor profitability of the company, workers' wages are low.

The company’s mechanical processing equipment is TX6111C/1W horizontal boring machine, T617 horizontal boring machine, T611A horizontal boring machine, Z9050X16/1 radial drilling machine, XK6330 CNC radial milling machine, B1-43 arc milling machine The C512 single-column vertical lathe and so on are all very old and outdated equipment. Among them is the TX6111C/1W horizontal boring machine, which can process a wire with a processing accuracy of one wire.

During our visit, we not only found that the equipment was backward, but also found many problems, such as: the floor was dirty, the processed iron filings were not cleaned in time; machine tools, materials, etc. were not placed neatly, and there was no area management ; Problems such as backward and irregular management. The management is not as good as the previous enterprise, which just reflects the importance of advanced management.

(4) Liuzhou Liuhe Fangsheng Machinery Co., Ltd.

September. The morning of June 12th

The last stop of our internship is Liuzhou Liuhe Fangsheng Machinery Co., Ltd., the company currently mainly provides production support for Dongfeng Liuqi Automobile, SAIC-GM-Wuling, FAW Liute, Yuchai Engineering Machinery, etc., and its products involve commercial vehicles,

MPV passenger cars, sedans, and mini cars. and construction machinery.

The company’s production also adopts an advanced management model and has high production efficiency. Sheet metal stamping is completed continuously on a production line from rough blank to finished product. The production of fuel tanks also uses advanced technology of automatic welding. The company's factory buildings are relatively new, the management is also very standardized, and the "5S" standard can be well implemented. The factory has advanced equipment, standard work processes, and some products can be produced on assembly lines.

The company was established in December 2002 with joint investment from Taiwan Liuhe Machinery Co., Ltd., Guangxi Xisheng Industrial Co., Ltd., and Taiwan Jiyi Machinery Co., Ltd. The company has 485 employees. people.

The company's current operating conditions are good, with product sales revenue of 203.53 million in 2008. It is estimated that in 2009, the sales revenue will be 250 million yuan and the profit and tax will be 30 million yuan. The company has advanced production equipment and uses advanced CAD/CAM systems for mold design and manufacturing. It has production and testing capabilities in stamping, metal cutting, welding, and painting, and has the ability to independently design and develop automobile parts.

The company’s main products include automotive parts assemblies (including passenger car body sheet metal parts, front/rear suspensions and swing arm suspensions), automotive container assemblies (including power steering oil tanks) , fuel tank, air reservoir), etc. Liuzhou Liuhe Fangsheng Machinery Co., Ltd. passed the ISO9001:2000 and QS-9000:1998 standard quality management system certification in 2003, and passed the ISO/TS16949:2002 standard quality management system certification in 2006. In the same year, it also passed the national "3C" certification.

However, due to the large number of us, it would bring inconvenience to the production, so we could only walk around the factory in secret under the leadership of the staff. We were unable to observe many details carefully, and there were many worthwhile The failure to understand the things we learned in detail left a small regret for our internship.