In the traditional machinery manufacturing enterprises, there are single small batch production models, batch (middle batch) production models and large batch production models. In a single batch of small batch production, due to a large number of general-purpose machine tools and process equipment, manual operations account for a large proportion, the level of automation of production is low, the amount of labor for processing and manufacturing products is large, and labor productivity is low. Even with the use of NC machine tools and machining centers, labor productivity cannot be compared with batch and mass production. In addition, because the workshops, sections, and groups take more specialized forms of production organization, the parallelism and continuity of the production process are very poor, so there are more breaks in production. All of these factors make production management complicated, even if ERP is used. It is also difficult to solve the single-piece batch production optimization problem, which affects the extension of the production cycle of the product manufacturing, the slow turnover of the working capital, and thus the product cost. Under mass production conditions, due to the large output, relatively few product varieties, and relatively stable production, it is possible to use partial automation equipment, special equipment and special tools, clamps, and measuring tools. The proportion of manual operations is smaller than that of single-piece production. The amount of labor for the product has increased labor productivity. At the same time, as some production processes are organized according to the principle of object, the equipment is arranged according to the flow direction of the process, the continuity and parallelism of production are high, and the production capacity of various links is calculated based on the main products of repeated production. The proportional relationship between them is also relatively reasonable, and the interruption time of the production process is correspondingly reduced. All of these have created certain conditions for shortening the production cycle of products, accelerating the turnover of working capital and reducing the cost of products, and the economic technologies for batch production. The index is higher than the single piece production. In mass production, due to the extensive use of highly efficient automation, semi-automated equipment, special machine tools, and specialized process equipment, the automation level of production is high, the proportion of manual operations is reduced to the minimum, and labor productivity is increased and product labor is reduced. The favorable conditions. From the analysis above, the technical and economic benefits of the company follow the law of mass, and the larger the batch, the lower the cost.
On the other hand, the type of manufacturing mode of an enterprise depends on the number of products and the stability and repeatability of production. What kind of breed rotation method is used to determine the volume of each product is a specific method and method of production.
In the machinery manufacturing industry, there are many types of products, and the structure and process are complicated. However, economic development and scientific and technological advancement require continuous trial production and production of a large number of new products, plus the user's requirements for product customization. The production of parts and the production of small batches are not only indispensable, but also a trend of development. This determines that 70 to 85% of the machinery manufacturing enterprises belong to the batch production mode and the single piece production mode. Therefore, research on batch production mode and single-piece small-scale production mode is a major issue for the development of enterprises.
According to Luo Mohui, CEO of Jinmo.com's machine tool network, some companies are already making changes to the manufacturing model, such as Dalian Machine Tool Group. Although in recent years, Dalian Machine Tool has been increasing the adjustment of its product structure, product level, management mode, and manufacturing mode. However, since production has always been in a full-load state, no adjustment has been made to the manufacturing mode. When the impact of the global economic crisis has not yet fully emerged, Dalian Machine Tool has been keenly aware that the opportunity for adjustments has arisen, and has therefore dared to challenge the traditional manufacturing model. Looking at the world machine tool industry, even if it is a more developed country, the production of machine tools has been using manual operation since ancient times. The Dalian Machine Tool, after successfully implementing the major product design and production scale, has undergone a near-subversive transformation of the traditional machine tool manufacturing philosophy and manufacturing model. To sum up in a simple way, it is to use the mass-production manufacturing model of a car to produce machine tools. The so-called change of manufacturing mode is the application of mass production mode, which combines the high-precision and high-efficiency equipment produced by Dalian Machine Tool with integrated and information-based means to form automatic processing and assembly lines and implement assembly line operations. That is to say, from the machine tool's raw line up to the finished product, they are all running efficiently on the line. The transformation of this manufacturing mode has not only greatly reduced the number of labor, increased the production efficiency, reduced the production cost, but more importantly greatly improved the product accuracy and reliability. It is understood that the assembly of lathes and CNC machine tools at Dalian Machine Tools has now undergone a change in the manufacturing model. All of them have been “on the line†and its production efficiency has attracted the attention of peers. In the past, the Group’s lathe factory had more than 2,800 people, and it had a maximum of 90 days a day. After the "launching" of the lathe bed, there are only 400 people now, and at least 150 out of one day. Last year, Dalian Machine Tool invested a large sum of money again. We have two production lines, one processing line and one assembly line at the production base of Wafangdian lathes, which is even more advanced than the automobile production line (automotive production line is only used for assembly). These two lines After all turning up, the blank goes in and the product comes out. The transformation of the manufacturing model has not only greatly increased the production efficiency, reduced the production cost, but more importantly greatly improved the product accuracy. At present, the leading product of Dalian Machine Tool is definitely the mainstream product of the market, and users are very satisfied with it, because there is no error in the product from the automatic line, and it can meet the needs of users in time.
Another example is Beijing No. 1 Machine Group, which has been in the leading position of manufacturing industry in the application of information technology and has won the international award of CIMS project. However, the significant improvement in the efficiency of the company lies in the introduction of technology and management technology from advanced manufacturing countries such as Japan, Germany, and France. Through learning, the North has a deep understanding of the concept, development model and organizational framework of modern, world-class machine tool companies. Based on the modularization of product design, the production of a large-scale gantry milling machine with a width of 5m in the past has been applied to the production of a modular product. Month will be able to produce 2 units, the efficiency is astonishing. Behind this speed is a decade of solid transformational change. The number of employees decreased from 6,000 in 2003 to less than 2,000, and the management department reduced from 50 to 9 through two adjustments. Per capita labor productivity: increased from 70,000 to 80,000, a sharp contrast shows the effect of manufacturing model transformation.
Through the above two enterprise practices, it is feasible and effective to adopt the advanced manufacturing mode for the change of the batch production mode and the single-piece small-scale production mode.
The “batch†in the traditional batch rule refers to the quantity of products, but due to the economic development and advancement of science and technology, it is necessary to continuously produce a large number of new product varieties, and the user’s requirements for product personalization have been determined. 70 to 85% of the machinery manufacturing enterprises belong to the batch production mode and the single-piece small-quantity production model. How to apply batch laws to improve the batch and single-piece small batch production enterprises? Analysis of the most basic organizational production is the organization of the production process, based on the production process and then formed components, and finally become products. Batch can be decomposed into: product batch, component batch and process batch. In this way, in batch production mode and single-piece small-quantity production model enterprises, although it is impossible to form batch production requirements for large-volume production enterprises, according to the development of the concept of batch rules, the batch production of parts and processes can be organized to achieve mass production. advantage.
Production R&D mode of mass customization production mode (1) Inheritance of product information, although there are certain differences in the appearance and function of different customized products, some of them have certain similarities, so that they can be fully utilized. The principle and method of group technology, inheriting the product information that has passed the test of production practice, inherits the product information and manufacturing process information of the past and improves the maturity of the product; at the same time, the design of a new product no longer needs to be started from scratch and is greatly shortened. Product design cycle. Make full use of product functionality and structural similarity to develop a variety of modular technologies, including Component-sharing modularity, Component-swapping modularity, and main-part adaptability module technology (Cut-to-fit Modularity), Bus modularity, and modular modularity.
(2) Development and design process reorganization. Design methods generally accepted by designers are based on functional design methods, and each new product design will be independent and brand new. Mass customization does not emphasize designing new parts but applying mature parts (modules). Combining new products, it analyzes and reorganizes key processes in order to combine previously artificially separated but interrelated activities. Product design for mass customization includes two major parts: new product development and custom product development. New product development Based on the analysis of market forecasts and the actual capabilities of the plant, the design of new products and standard modules, this process needs to be predictable and innovative, but also has certain risks, and its success or failure will greatly affect The fate of the enterprise; custom product design is a combination of conventional design, mainly based on the specific needs of customers in the contract to select the appropriate parts and components portfolio, and according to specific parameters of the standard module variant design.
The serialization, generalization, standardization and modularization of product structure are based on the inheritance of product information, the product R&D model of mass customization production mode, and the traditional product structure is generalized, serialized, standardized and modularized, and created for mass customization. condition.
Application of information technology, in-depth integration, implementation of enterprise mass customization is the advanced manufacturing technology, information technology is to achieve advanced manufacturing technology support technology, application of information technology implementation of mass customization is the integration of the two companies in the embodiment and goals.
The use of information technology to achieve mass customization Product development and manufacturing new models Product structure of the modular These technologies have been proposed in the 1950s and 1960s, but the modular design system for building products by hand is more complex (Beijing No. 2 Machine Tool Plant is In the early 1980s, it took 8 years to manually build a modular design system for external grinders. Since information technology could not easily support the modular design of product structures at the time, PDM had been blocked in the late 1990s. Management develops core PLM for enterprise information integration. At present, PDM functions include component management, structure configuration, and attribute data management in addition to graph management and process management. The deep application of component management, structure configuration, and attribute data management has created conditions for establishing a modular design system for products. It has become an important support for the new model of mass customization product development and manufacturing, and it is also the key to the role of PDM. The application of these modules forms a product design environment and work platform for mass customization production, which will change the traditional product design patterns and manufacturing meter models, and also provide technical support for changing the traditional enterprise economic development model.
On the other hand, the type of manufacturing mode of an enterprise depends on the number of products and the stability and repeatability of production. What kind of breed rotation method is used to determine the volume of each product is a specific method and method of production.
In the machinery manufacturing industry, there are many types of products, and the structure and process are complicated. However, economic development and scientific and technological advancement require continuous trial production and production of a large number of new products, plus the user's requirements for product customization. The production of parts and the production of small batches are not only indispensable, but also a trend of development. This determines that 70 to 85% of the machinery manufacturing enterprises belong to the batch production mode and the single piece production mode. Therefore, research on batch production mode and single-piece small-scale production mode is a major issue for the development of enterprises.
According to Luo Mohui, CEO of Jinmo.com's machine tool network, some companies are already making changes to the manufacturing model, such as Dalian Machine Tool Group. Although in recent years, Dalian Machine Tool has been increasing the adjustment of its product structure, product level, management mode, and manufacturing mode. However, since production has always been in a full-load state, no adjustment has been made to the manufacturing mode. When the impact of the global economic crisis has not yet fully emerged, Dalian Machine Tool has been keenly aware that the opportunity for adjustments has arisen, and has therefore dared to challenge the traditional manufacturing model. Looking at the world machine tool industry, even if it is a more developed country, the production of machine tools has been using manual operation since ancient times. The Dalian Machine Tool, after successfully implementing the major product design and production scale, has undergone a near-subversive transformation of the traditional machine tool manufacturing philosophy and manufacturing model. To sum up in a simple way, it is to use the mass-production manufacturing model of a car to produce machine tools. The so-called change of manufacturing mode is the application of mass production mode, which combines the high-precision and high-efficiency equipment produced by Dalian Machine Tool with integrated and information-based means to form automatic processing and assembly lines and implement assembly line operations. That is to say, from the machine tool's raw line up to the finished product, they are all running efficiently on the line. The transformation of this manufacturing mode has not only greatly reduced the number of labor, increased the production efficiency, reduced the production cost, but more importantly greatly improved the product accuracy and reliability. It is understood that the assembly of lathes and CNC machine tools at Dalian Machine Tools has now undergone a change in the manufacturing model. All of them have been “on the line†and its production efficiency has attracted the attention of peers. In the past, the Group’s lathe factory had more than 2,800 people, and it had a maximum of 90 days a day. After the "launching" of the lathe bed, there are only 400 people now, and at least 150 out of one day. Last year, Dalian Machine Tool invested a large sum of money again. We have two production lines, one processing line and one assembly line at the production base of Wafangdian lathes, which is even more advanced than the automobile production line (automotive production line is only used for assembly). These two lines After all turning up, the blank goes in and the product comes out. The transformation of the manufacturing model has not only greatly increased the production efficiency, reduced the production cost, but more importantly greatly improved the product accuracy. At present, the leading product of Dalian Machine Tool is definitely the mainstream product of the market, and users are very satisfied with it, because there is no error in the product from the automatic line, and it can meet the needs of users in time.
Another example is Beijing No. 1 Machine Group, which has been in the leading position of manufacturing industry in the application of information technology and has won the international award of CIMS project. However, the significant improvement in the efficiency of the company lies in the introduction of technology and management technology from advanced manufacturing countries such as Japan, Germany, and France. Through learning, the North has a deep understanding of the concept, development model and organizational framework of modern, world-class machine tool companies. Based on the modularization of product design, the production of a large-scale gantry milling machine with a width of 5m in the past has been applied to the production of a modular product. Month will be able to produce 2 units, the efficiency is astonishing. Behind this speed is a decade of solid transformational change. The number of employees decreased from 6,000 in 2003 to less than 2,000, and the management department reduced from 50 to 9 through two adjustments. Per capita labor productivity: increased from 70,000 to 80,000, a sharp contrast shows the effect of manufacturing model transformation.
Through the above two enterprise practices, it is feasible and effective to adopt the advanced manufacturing mode for the change of the batch production mode and the single-piece small-scale production mode.
The “batch†in the traditional batch rule refers to the quantity of products, but due to the economic development and advancement of science and technology, it is necessary to continuously produce a large number of new product varieties, and the user’s requirements for product personalization have been determined. 70 to 85% of the machinery manufacturing enterprises belong to the batch production mode and the single-piece small-quantity production model. How to apply batch laws to improve the batch and single-piece small batch production enterprises? Analysis of the most basic organizational production is the organization of the production process, based on the production process and then formed components, and finally become products. Batch can be decomposed into: product batch, component batch and process batch. In this way, in batch production mode and single-piece small-quantity production model enterprises, although it is impossible to form batch production requirements for large-volume production enterprises, according to the development of the concept of batch rules, the batch production of parts and processes can be organized to achieve mass production. advantage.
Production R&D mode of mass customization production mode (1) Inheritance of product information, although there are certain differences in the appearance and function of different customized products, some of them have certain similarities, so that they can be fully utilized. The principle and method of group technology, inheriting the product information that has passed the test of production practice, inherits the product information and manufacturing process information of the past and improves the maturity of the product; at the same time, the design of a new product no longer needs to be started from scratch and is greatly shortened. Product design cycle. Make full use of product functionality and structural similarity to develop a variety of modular technologies, including Component-sharing modularity, Component-swapping modularity, and main-part adaptability module technology (Cut-to-fit Modularity), Bus modularity, and modular modularity.
(2) Development and design process reorganization. Design methods generally accepted by designers are based on functional design methods, and each new product design will be independent and brand new. Mass customization does not emphasize designing new parts but applying mature parts (modules). Combining new products, it analyzes and reorganizes key processes in order to combine previously artificially separated but interrelated activities. Product design for mass customization includes two major parts: new product development and custom product development. New product development Based on the analysis of market forecasts and the actual capabilities of the plant, the design of new products and standard modules, this process needs to be predictable and innovative, but also has certain risks, and its success or failure will greatly affect The fate of the enterprise; custom product design is a combination of conventional design, mainly based on the specific needs of customers in the contract to select the appropriate parts and components portfolio, and according to specific parameters of the standard module variant design.
The serialization, generalization, standardization and modularization of product structure are based on the inheritance of product information, the product R&D model of mass customization production mode, and the traditional product structure is generalized, serialized, standardized and modularized, and created for mass customization. condition.
Application of information technology, in-depth integration, implementation of enterprise mass customization is the advanced manufacturing technology, information technology is to achieve advanced manufacturing technology support technology, application of information technology implementation of mass customization is the integration of the two companies in the embodiment and goals.
The use of information technology to achieve mass customization Product development and manufacturing new models Product structure of the modular These technologies have been proposed in the 1950s and 1960s, but the modular design system for building products by hand is more complex (Beijing No. 2 Machine Tool Plant is In the early 1980s, it took 8 years to manually build a modular design system for external grinders. Since information technology could not easily support the modular design of product structures at the time, PDM had been blocked in the late 1990s. Management develops core PLM for enterprise information integration. At present, PDM functions include component management, structure configuration, and attribute data management in addition to graph management and process management. The deep application of component management, structure configuration, and attribute data management has created conditions for establishing a modular design system for products. It has become an important support for the new model of mass customization product development and manufacturing, and it is also the key to the role of PDM. The application of these modules forms a product design environment and work platform for mass customization production, which will change the traditional product design patterns and manufacturing meter models, and also provide technical support for changing the traditional enterprise economic development model.
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