Tongkuai Internet Intelligent Manufacturing | Jilin Jinguan Electric Co., Ltd

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Tongkuai (China) Co., Ltd

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Date: 2022-02-16Read: 6

There is still great potential for improvementMr. Wu Zongnan, the production director of Jilin Jinguan Electric Co., Ltd., smiled and said that it seemed to be a confidence in their own production capacity, as well as an expectation and requirement for their future. Outside the window is the heavy snow that has fallen in Changchun since the beginning of winter this year, and at a glance, it is a large blank space scattered on this old industrial base land in winter.

Unlike the silence and coolness in the snow, the production workshop of Golden Crown is a different scene:

Laser cutting machines and automated punching machines are working tirelessly; The operator opens the whole package of raw material boards of different specifications and places them on the feeding trolley of the automated material warehouse; Stacker cranes transport pallets back and forth, delivering different boards to different equipment according to orders, and sending completed intermediate products to the next process; The automatic bending unit connected to the material warehouse and the manual bending station are used to form and process the finished products according to the needs. This is the Tongkuai automated sheet metal processing line completed at the end of 2017, specially designed according to the characteristics of processing Golden Crown switchgear products.

As a manufacturer of intelligent switchgear in the three provinces of Northeast China and even across the country, Jinguan Electric has been thinking about how to empower the manufacturing industry and reignite the vitality of the old industrial base.Until they met Tongkuai, they found the key to solving the problem.

Proactively transform and empower traditional manufacturing

The potential is enormous, and Mr. Wu is referring to this production line.The existing production capacity cannot meet our needs, and this opportunity has prompted us to start thinking about ways to improveMr. Wu introduced it. The processing of switchgear belongs to typical discrete manufacturing, and the development trend of multi variety, small batch, and customized manufacturing industry has put forward higher requirements for the efficiency and flexibility of the production process.

Like most traditional sheet metal factories, the production mode of Jinguan in the past was mainly single machine single station production. The balance of rhythm and information exchange between different equipment brought great difficulties to production planning and management.We produce according to orders, and frequent material and mold changes not only bring additional workload, but also often mean downtime and efficiency losses due to coordination with logistics and other departmentsIt's time to make a change.

Jinguan Electric has successively inspected numerous domestic and foreign equipment suppliers and drawn up a list.

I have looked at many solutions and found that some of the equipment manufacturers' technologies are quite good, but overall I feel that they are not enough. The technical performance of a single device is certainly important, but it must meet the high flexibility requirements of production according to orders. The ability to connect the entire line across processes and excellent stability and flexibility play a key role. The TruConnect intelligent manufacturing solution from Tongkuai has deeply impressed the management of Jinguan Electric, helping Jinguan take the step towards intelligent manufacturing.

Interconnected intelligent manufacturing, stimulating new momentum

Sure enough, the effect *.

First of allSingle machine performance.

The continuous processing capability has significantly increased. In the past, domestically produced equipment needed to replace consumables every week, but the Tongkuai equipment has not been replaced for a year. The protective mirror and ceramic ring in the laser head never need to be maintained. The service life of the punch mold is also 3 to 4 times longer

Then comesSystem capability.

A complete switch cabinet sheet metal processing system is formed through an automated material warehouse of over 100 meters, connected to 1 laser cutting machine, 1 automated punching machine, 1 manual bending machine, and 2 automated bending units. With only one shift, it is possible to achieve a production capacity of 60 units per day and nearly 1500 sets per month during peak hours. The production capacity has doubled, but the demand for operators has decreased by half, allowing more manpower to be allocated to more creative work.

We put the core products of JinGuan on this new line for a trial, and the processing capability is very strongMr. Wu pointed to one of the products and explained in detail, 'This 2mm aluminum zinc plated cabinet requires bending after pressing both sides. For the convenience of subsequent assembly, high precision is required.'. ”Before using the Tongkuai equipment, this product requires 2 sets of equipment, 2 sets of molds, and manual operation by 5 people to complete production, and the processing parameters need to be continuously adjusted. The automatic bending unit of Tongkuai can be continuously processed with just one parameter setting, without the need to adjust the processing parameters. Moreover, one machine and one set of molds can do it. The processing capability has been significantly improved.

Another benefit of automated machining systems is that the workload is significantly reduced.The previously busy inbound and outbound work has also been replaced by TruTops Fab's material management module, which automatically records the inventory quantity of various boards, accurately and conveniently. The various materials required for each workstation of the production line are managed and distributed through the material warehouse management system, which is also automatically completed by the material warehouse. The turnover rate is high, and only planning is needed without the need for on-site scheduling.

The on-site management has improved a lot. Previously, material stacking and management took up a lot of space and energy, but now it's better, "Mr. Wu pointed to the Tongkuai automation line," because the things that require manual management have been greatly reduced

The solution to old problems seems to be ready, but the transformation and upgrading from traditional manufacturing to intelligent manufacturing is still a step away.

Craftsmanship in polishing, taking you to the next level

What are the difficulties in the process of transforming intelligent manufacturing? When asked this question, Mr. Wu pondered for a moment and said:“run inIntegration refers to the integration of people and equipment, the integration of old processing thinking with new technologies, the integration of existing processes with new models, and the integration of cross departmental cooperation and optimization. Only when the equipment is well adjusted can it fully utilize its advantages and capabilities.

From the design phase onwards, engineers at Tongkuai incorporate the client's situation into the design considerations, with production needs as the center and production processes as the basis, combined with the on-site environment, and incorporating supporting departments into the planning scheme. Through the early stage of accompanying production with Tongkuai and a year of running in, Jinguan has gradually transformed from its original level in terms of management philosophy, production habits, operation and maintenance methods, etc., from top to bottom.

With the help of the TruTops Fab production management system, we have digitized the production process and monitored the processing quantity, processing time, material utilization, and other aspectsThis transformation makes the production site instantly transparent and clear for managers. The engineers from Tongkuai helped Jinguan establish a production management method that is different from the single machine processing mode, but the transformation is still ongoing. In the next plan, Jinguan Electric will connect the business process with production and achieve information synchronization with the help of the Tongkuai Production Management System. At the same time, incorporating the programming and design process together, changing the existing way of programming work, and comprehensively improving the efficiency of programming work.

The equipment efficiency has increased, and the early planning and preparation must keep up, "Mr. Wu said with a smile,We can go further and believe that by fully releasing equipment capacity, our production capacity can reach three times the current level

In the context of the "winter" economic environment, the term "consumption downgrade" that we often mention in daily life is often a sense of helplessness for individuals living in the larger environment. When mapped to the manufacturing industry, it often leads to a vicious cycle of abandoning the pursuit of quality, sinking into the target market, and then falling into the quagmire of price wars. However, Jinguan Electric has taken a different approach, actively pursuing self upgrading and planning for the future "recovery into spring". The transformation of intelligent manufacturing is a key that Jinguan Electric has found.

Revitalizing old industrial bases is an important issue in the current development of China's manufacturing industry. Only through supply side reform and the elimination of backward production capacity can new vitality be unleashed in the context of industrial technology and mode concept innovation, and a new future be written on the blank space of this land.

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