The rapid development of China's automobile industry has led to the rapid growth of the equipment industry, in the context of Industry 4.0, "intelligent manufacturing" is becoming increasingly popular among car companies and parts suppliers, which has brought new development potential and opportunities to the equipment manufacturing industry.
On October 26, 2021, Dingjie Software held the "Into the Digital Wisdom Factory Demonstration Enterprise - Fuzhou Mingfang Industry" activity, dozens of backbone representatives of manufacturing enterprises walked into the Mingfang intelligent production workshop, from the cost, quality, efficiency management issues as the starting point, to discuss and understand how to find a shortcut to intelligent manufacturing promotion, and accelerate the pace of turning to factory intelligence.
About Mingfang
Fuzhou Mingfang Auto Parts Industry Co., Ltd. (hereinafter referred to as "Mingfang"), established in 1995. The company mainly develops, designs, and manufactures auto parts and electronic devices, disc brake assemblies, molds, and sales of homegrown products and provides related after-sales service. It is an excellent supplier of Dongfeng Liu, GAC Mitsubishi, Southeast Motor and other enterprises.
<h1 class="pgc-h-arrow-right" data-track="174" > Dingjie Auto Parts MOM program sharing</h1>
At the Mingfang event, Gao Lu, senior consultant of the Smart Factory Planning Department of Dingjie Software, brought the theme sharing of "Benefit-oriented Digital Factory Practice - Dingjie MOM Solution".
Senior Consultant of Dingjie Software Smart Factory Planning Department Gao Lu
Gao Consultant said: "All along, the manufacturing industry site management has faced many challenges, such as high industry standards, fierce market competition, high customer requirements, so that the complexity of the production site and the high standard of production requirements always form a strong contradiction, especially in the more complex auto parts industry at the production site, the contradiction is more prominent.
In order to achieve effective improvement of the auto parts manufacturing site, we need systematic ideas and tools to help parts companies achieve "lean and agile" manufacturing and standardized management. ”
Ideas and tools that require a system (auto parts)
As an expert in intelligent solutions in the auto parts industry, Dingjie Software has successful implementation experience of hundreds of customers in the auto parts industry, and the MOM platform built can help auto parts companies build a comprehensive digital intelligent manufacturing system to achieve reliable quality, continuous improvement, punctual and agile delivery, and continuous cost reduction.
The core MOM business blueprint that supports digital transformation
On the Dingjie Software MOM platform, the core business blueprint supporting digital transformation covers:
Six business centers: dispatch and dispatch center, production task center, material JIT pull center, quality control center, production resource center, lean performance monitoring and management center
A major industry system: auto parts quality assurance system
A major technology platform: MOM technology platform
<h1 class="pgc-h-arrow-right" data-track="41" > the core tool to support field management and digital transformation</h1>
1. Agile Supply Chain Response Center: Coordinated agile supply chain optimization
Based on the integration and collaboration of ERP, SRM, MES, WMS and other systems coordinated by the MOM platform, an agile supply chain system is built, the supply chain breakpoint is reduced, the collaborative control of sales, production and material supply is realized, and the rationality and accuracy of the production plan are improved.
2, lean production center: the core of the enterprise production management improvement
Based on the business management platform with on-site improvement as the core, it realizes the full control of on-site man-machine material law and environment measurement, responds quickly and reduces process waste.
3. Material JIT pull center: realize punctual material supply and distribution
Based on the core idea of JIT, the right products are delivered to the right place at the right time in the right quantity and at the right price, and the material supply is guaranteed with systematic tools.
4. Quality control center: to achieve quality prevention in advance, control during the event, and traceability after the event
Advance prevention: Realize 4M change management, prevent problems before they occur, and notify the front-line management personnel of the plan change within 2 days, from "people looking for things" to "finding people and finding the right people";
In-process control: The whole process quality SPC control tool realizes comprehensive process quality control through QC seven methods, multi-dimensional analysis of quality problems, and one-click chart analysis.
Traceability after the fact: Based on the comprehensive quality traceability platform, the comprehensive forward and reverse traceability of man-machine material law and environment measurement is realized
5. Production resource center: comprehensive control of equipment and knife mold fixtures
Comprehensive preventive maintenance management of TPM based on system tools for comprehensive equipment and knife mold fixtures.
6. Lean performance and management center: the establishment of three-level monitoring indicators of enterprises
Execution and operator from the front line (position, production line daily efficiency)
Functional Managers (Department, Shop Floor Performance)
Business decision makers (overview), establish three-level monitoring indicators for enterprises.
7. Auto parts quality ensures the implementation of the system
System landing tool based on IATF16949.
<h1 class="pgc-h-arrow-right" data-track="175" > Mingfang case sharing</h1>
Manager Tang Yanqiao of Mingfang shared the informatization process of Mingfang for the guests online and introduced the intelligent manufacturing project of Mingfang in detail.
Manager of Fuzhou Mingfang Auto Parts Industry Co., Ltd. Tang Yanqiao
Manager Tang said: "At present, the manufacturing industry is facing a key node in the transformation of intelligent manufacturing, Mingfang actively seeks breakthroughs and changes, and works together with Dingjie Software to focus on production objects such as products, materials, production work orders, warehousing and logistics, and production factors such as people, machines, materials, laws, and rings, through the means of intelligent manufacturing, to achieve the synergy of information flow and physical flow, support the lean production of single-piece flow, and continuously improve Mingfang's service capabilities." ”
--- mingfang informationization starting point---
External factors: improve product quality, realize the whole process of quality traceability (according to the serial number traceability).
Internal factors: improve production efficiency, reduce production costs, operating costs.
--- Mingfang Intelligent Manufacturing Practice Path--
1. Improve production preparation capacity
Kanban molding
Kanban molding displays the information related to the expected production work order in a consolidated display, feedback the status of key elements through different colors (green- normal; yellow - incomplete; red - abnormal), review and confirm the readiness status one by one, and ensure that the production starts on time;
Timely control of abnormal information in the production process and rapid response.
SOP push
When starting work, the latest version of the work instruction is automatically pushed to each workstation, reducing production preparation time.
2. Improve supplier management capabilities
Incoming storage solutions
Supplier platform displays all Kanban and planned orders;
The supplier delivers the goods according to the delivery time of Mingfang and posts the bar code according to the requirements of Mingfang;
PDA according to the material bar code to do on-site inspection of materials and quantities;
IQC conducts inspections based on the quantity reported for inspection.
Supplier Pre-Delivery & Yield Kanban
Through the kanban arrangement in the receiving area, the delivery personnel of each manufacturer clearly know the company's quasi-delivery rate and yield rate, so as to urge suppliers to improve the quasi-delivery rate and product yield.
Supplier delivery management
Check whether the kanban is hung incorrectly, resulting in abnormal picking on-site picking;
Through eKB, we promote the timeliness of IQC and warehouse warehousing, so that the actual logistics and data flow are consistent, and the timeliness and accuracy of data are guaranteed.
3. 4M change management
Personnel change management
Through the post management mechanism of fixed post, one post, one person and multiple posts, personnel skill level, skill experience management, induction level inspection, OEM management and other mechanisms, reduce the quality fluctuation caused by human reasons.
Device change management
Preventive maintenance tips for parts and equipment to prevent problems before they occur;
Spare parts procurement plan management, reduce equipment failure, improve equipment utilization;
Equipment, mold fixture failure and other unexpected situations quickly grasped, timely response.
Item change management
Replacement of new and old materials, early confirmation of main supplier changes in materials;
Unexpected situations such as missing materials and bad materials are quickly grasped, and timely feedback and response are given to ensure continuous production.
Construction method change management
Timely notification of work changes/set changes to front-line executives to promote planned operations and improve quality.
4. Whole process quality traceability
Through bar codes, equipment interconnection and other ways to collect materials, quality inspection, production process, packaging and other information based on process cards, to achieve the whole process of quality traceability management from procurement, production, sales, logistics and other links.
5. Visual management
Real-time display of production line progress, quality, efficiency and other information, increase on-site transparency, speed up response speed.
--- the benefits of the project at this stage---
Dingjie Informatization has helped Mingfang achieve significant improvement in the benefits of six major management aspects, such as cost, quality, efficiency, quality traceability and customer satisfaction.
After the meeting, the guests also walked into the Mingfang factory, personally visited the manufacturing production site to feel the practical achievements of Mingfang intelligent manufacturing, conducted in-depth exchanges with the senior consultants of Dingjie, and discussed the practical path of the intelligent transformation of enterprises.
From the trend point of view, the digital and intelligent transformation of enterprises will be the core means for auto parts enterprises to achieve management upgrades, cost reduction and efficiency increase, and with the guidance of the previous national intelligent manufacturing policy and the practical accumulation of related technologies and programs, the auto parts industry has been in the best period of transformation and change.
Rooted in the auto parts industry for more than 30 years, Dingjie has formed a complete solution for the entire supply chain, and more than 600 enterprises in the general system, volkswagen system, Ford system and southeast system have continued to benefit through Dingjie's auto parts industry program, which has been unanimously recognized by customers. Dingjie is willing to help the majority of auto parts enterprises, quickly get rid of the predicament, and realize the transformation and upgrading of digital intelligence!
Welcome to pay attention to Dingjie Intelligent Manufacturing, regularly harvest manufacturing digital transformation cases and cutting-edge solutions, and grasp the first information of the manufacturing industry!