Transferred from: Popular News - Popular Daily
More than 1,100 sets of numerical control precision equipment have been purchased, and 35 new intelligent automatic production lines have been installed...... In just a few years, Shandong Runtong Gear Group Co., Ltd., located in Xintai City, has invested nearly 800 million yuan to carry out an unprecedented digital and intelligent comprehensive upgrade of its production line. On October 16, the reporter went to the company for on-the-spot interviews.
However, with the rise of new energy vehicles, single products, backward technology and low production capacity make enterprises in the wave of market changes, once faced with the dilemma of limited development, as if becoming a "bystander" of the times. In order to resonate with the market, transformation is imperative.
"At that time, the company's senior management had a heated discussion, some leaders were pessimistic about the market prospects of new energy commercial vehicles, believing that affected by the battery and charging efficiency, new energy commercial vehicles, especially long-distance transport vehicles, are unlikely to achieve electrification, and fuel commercial vehicles have a good prospect, the existing equipment can also meet the market demand, and now large-scale investment transformation into a new track, if the wrong choice will be detrimental to the company's development." Jiang Yong, deputy general manager of the company, said.
After careful consideration and repeated demonstrations, Runtong Gear unified its thinking: if the enterprise wants to enter a new track, it must take the road of digitalization and intelligence. They rose to the challenge and launched a comprehensive digital transformation plan in 2018. The company has invested 660 million yuan to carry out numerical control transformation of nearly 2,000 pieces of equipment in the factory area, of which nearly 60% of the newly purchased equipment has realized a gorgeous turn from traditional manufacturing to intelligent manufacturing.
Walking into the No. 2 production workshop of Runtong Gear, I saw the automatic robotic arm waving dexterously, accurately and efficiently executing every production instruction, and the gearbox gear, differential housing and other products on the production line were rolled off the production line one after another. Next to an automated half-shaft gear production line consisting of four machines, only one worker is busy. Li Xia, the director of the company's office, said, "In the past, this line required at least seven or eight people. ”
Today, through digital and intelligent transformation, the company's high-tech equipment has successfully replaced some traditional human operations and become a "capable leader" on the production line. It is understood that the workshop has 35 intelligent production lines, 100 workers can produce more than 40,000 products per day, to complete, in the past, at least 500 people need to complete the same work.
More importantly, the digital and intelligent transformation of Runtong Gear has improved the tooth direction accuracy of the reduction gear produced by the enterprise from the original six levels to four levels. "From the upper end to the lower end, the parallel error does not exceed 0.7 microns, according to the national standard, it is a four-level accuracy, and we have now reached 0.1 microns, which belongs to the aviation gear level, which is the leading in the industry." Jiang Yong introduced. It is understood that the tooth accuracy standard of pure electric commercial vehicle gears is 4-6 levels, which has successfully opened up the new energy vehicle market for enterprises.
At present, the pure electric commercial vehicle gears produced by the company have been mass-produced, and it has become a strategic supplier of domestic new energy commercial vehicle giants such as China National Heavy Duty Truck, Guangxi Sheng, and Suzhou Green Control. It is particularly worth mentioning that Guangxi Sheng, as the largest supplier of Yutong bus axles, has a market share of up to 80%, and the electric gears used in these axles are all produced by Runtong Gear. At present, the company generates nearly 50 million yuan of revenue from the field of new energy commercial vehicles every year.
Even so, the pace of digital and intelligent transformation of Runtong gear has not stopped. At present, the company is actively building a 5G digital factory. "In the future, we will fully integrate the entire enterprise management system into the smartphone, so that we can have a full range of insights into the key elements of the enterprise with just one mobile phone: from equipment operation to personnel allocation, from material inventory to financial management, and even the overall management overview." In the central control room of the enterprise's 5G digital factory, Li Xia described to reporters a magnificent blueprint for the enterprise's 5G digital factory.
It is reported that this innovative project is expected to have a total investment of 120 million yuan, and has been piloted in the No. 2 production workshop with a leading level of automation. "We have installed data collectors for 100 pieces of equipment in the workshop, and the operation and maintenance of the equipment will be displayed in real time on the large screen, which is clear at a glance." Li Xia pointed to a smart whiteboard under the large screen while introducing, which dynamically displayed the equipment repair details uploaded by workers through their mobile phones.
"In the past, equipment failures often required cumbersome escalation processes, which not only took a lot of time, but also could adversely affect production schedules. Now, thanks to the construction of the 5G digital factory, workers can upload the fault situation in just a few simple steps, and the maintenance person in charge can quickly respond and make proper arrangements, truly realizing the accuracy and efficiency of the maintenance work. Li Xia said.
With the continuous collection and accumulation of a large amount of production data, the company plans to build a virtual factory platform on the Internet. In the R&D phase of new products, they can simulate and test them directly in the virtual factory, which greatly saves human resources and R&D costs.
Nowadays, with a series of digital and intelligent transformation and upgrading measures, the commercial vehicle gear has accounted for 24% of the national market, and in 2020, the company won the provincial single champion enterprise with its outstanding performance. This year, Runtong Gear is actively sprinting for the domestic individual championship. According to statistics, in the first half of this year, the company's sales revenue was 760 million yuan, a year-on-year increase of 17.1%, and the company showed a continuous growth trend.
(Popular News reporter Liu Tao, Tai'an Daily reporter Cui Dongxu, correspondent Xu Changhong, Niu Wei)