Worker Pioneers Solve Problems, Innovate and Create for Production

Due to the high failure frequency of the three-slot locking and clamping press equipment, the longest downtime of a single shift was 193 minutes, which led to the cylinder head sub-assembly line could not be stable for the main line production, and there is a risk of stopping the line at any time.
Chongqing branch engine factory assembly workers vanguard three-slot special group immediately targeted solutions, around the material, equipment, technology and other factors in an orderly manner, cumulative findings of the valve seat is not sucked up, take the seat cylinder is not returned, the sensor can not be sensed and so on 7 kinds of problem patterns.

While calling for downtime for maintenance and organizing the team to assess the implementability of the measures, the Pioneer Desk also quickly pulled the main line to adjust the production model, and the sub-assembly line was temporarily adjusted to a “12+12” production mode to establish a cylinder head cache, to ensure that the production schedule of the entire engine was not affected.
In the end, the team restored equipment stability by replacing the seating head seals, cleaning the reclaim mandrels and other corresponding measures.

Since the N15A FR engine switched to dual mass flywheel, the FTQ of the automatic tightening equipment for OP2320 flywheel tightening on the assembly line fluctuated greatly, affecting the production efficiency. In response to the unqualified data collected, the No. 1 station analyzed the tightening process and photo positioning parameters, and finally locked in the equipment before tightening photo positioning, the camera grabbed the bolt range offset, resulting in tightening shaft alignment deviation.

When the maintenance colleagues retrained the image template, the members of the No. Desk brainstormed to develop ideas and proposed to expand the camera recognition range, adjusting the program from recognizing 1 to 2 bolts, and increasing the exposure value on the original basis. After the expansion, the camera can quickly find the comparison point for localization, the high exposure value facilitates the ability to take photos for identification, and the FTQ of the equipment has steadily increased from 96.6% to 99.2%.

In response to the assembly line OP2090 collaborative robot tightening ignition coil cover equipment due to the hexagonal bolt alignment difficulties, lack of precision resulting in low FTQ, the team through independent innovation design and processing of sleeve positioning aids, the use of “human-machine interaction” to pull the collaborative positioning, optimization of the tightening control logic to lock the unqualified position to facilitate the collection of data and other optimization measures. Through a series of optimization measures, the team successfully increased the tightening qualification rate from 88% to 99%, and effectively reduced the number of reworks to 2 units per shift.

Assembling workers' vanguard station vigorously promote the construction of digital workshop, in the existing intelligent, intelligent production and operation system to break new ground, the courage to innovate, have confidence, and continue to overcome the difficulties in striding forward.

Within a short period of 18 days, No. Desk member Jun Zhang completed program writing and data collection, and intelligently upgraded the VCM rework K-value recommendation function to realize an automated K-value optimization system with more than 20 practical functions, such as automatic collection of unqualified data of engine valve lash, batch comparison and analysis, and optimization of K-value recommendation, so as to reduce the pressure of rework for the production line, and to increase the accuracy rate and traceability of rework.

In response to the manufacturing system's call for cost reduction and efficiency, the engine assembly shop and ME collaboration, through horizontal and vertical comparisons of continuous deep excavation of the site can be optimized workstation. Through the introduction of domestic collaborative robots, the different models of engines in each manual workstation scattered tightening work after the flexible combination of automation transformation, to achieve a single shift job optimization of 2, cost savings of 480,000 yuan, for the construction of advanced production system structure, to create a solid foundation for intelligent manufacturing plant.

More than ten years of splendor, advance into the new era! Star Power Factory Assembly Worker Pioneers are working together, constantly deepening practice, innovation and creation, sweating to help the company reach its production goals, and giving back to the company with practical actions.