- Learn from the 'two plates' Martian lean manufacturing

Every year before the New Year, people are accustomed to taking inventory of what they have done in the past year. There will always be a highlight moment in the inventory process. For the integration of Martian, October 19, 2017, it is special day.

On this day, the assembly line with an annual output of 100,000 Westerner assembly ceremony was held in the production workshop of Hesse's Jianshan headquarters. With the common last countdown, the 100,000th machine covered with red silk slowly moved from the production line Up and down, marking a historic moment in the integrated cooking industry is being witnessed.Marx's next goal is to produce 20,000 units, which means that a new round of capacity offensive is brewing.

Figure 1: In 2017, the assembly line of Mars will be 100,000 units off the assembly line

Under the highlight made by 100,000 Taiwan units, the efficiency of the Martian production technology upgrade over the past year is an accumulation of lean process-oriented processes. It is not hard to imagine that the one Taiwan integrated cooking stove before us has the perfect off-line , The realization of the process, until the formation of large pieces, are initially welded from a few pieces of small steel plate. 'Do not underestimate the welding of the two plate forming, the technical difficulties here' Martian integrated stove production Minister Liu Qiuyong said to me.

In the past year, Liao Chiu-yong said in a straightforward manner that "leanization" has become the main line of production running through the Martian. In order to ensure that every process is controllable, the Martians introduced a series of changes in the workshop to solve many technical difficulties. Representative, that is, the skills of the welding process.

So, on how to lean, how to make, let's start with the welding of these two plates.

Win the difficult task of integration stove tough fight

In people's visual impression, the steel is so hard, airtight. However, even when the two plates together, welding fusion process, it is inevitable for a variety of reasons lead to some of the pores, a direct impact on airtightness and product Exterior.

Liao Qiuyong told the author, the team quickly set up eight capture team, worked overtime to tackle the problem, 'we use exclusion test to overcome difficulties, such as protection of the argon purity is not high enough, the product to be welded parts rust oil, welding stability Deviation, etc., the final multi-verification, the problem lies in the area of ​​the machine protector, we expanded from 10 cm to 20 cm, 90% of the pores were blocked. 'At present, such problems have been a perfect solution, which It is undoubtedly a long-term accumulation of Martian production technology and lean manufacturing.

The greater difficulty lies in the integrated cooking stove section of the liner welding, for process personnel, from the outside to ensure that the internal non-porous welding, is tantamount to 'blind welding', which is also a persistent problem in the industry, The high degree of difficulty can be imagined.

According to Martian welding workshop director Wu Tingyou recalled, in order to disappear stomatal oxidation disappeared, first with the caliper, dial indicator, adjust the fineness, and then through the anatomy of defective products, improve the material with the degree of ... ... a difficult task Investigation, the entire team pondering this for several months, once wanted to give up .At the end or with the Martian staff dissatisfied with heart-breaking infatuation, after hundreds of tests to investigate, bite the teeth persevered.

Kung Fu pays off, overcome the team's insistence in return.In the team technician to adjust the gun focal length, the welding temperature is no longer loose, more concentrated sparks.The industry has finally been tough challenge! At present, the welding technology has been successfully applied to the X7Z, X2Z, Q5Z and a series of Martian steamer products.

It is worth mentioning that it is reported that Martians will introduce fully automatic welding lines for the steamer section in 2018, a measure that has taken refinement to a new height. In the future, Martians will further introduce platform-based production to follow the example of automobile production Mode, so that more advanced production line intelligent and modern.

The value of the process technology, simple is not simple

Nowadays, the product of Martian is leading the trend, especially in the integrated kitchen industry, 'Qiang Wang' Q5, which fully interprets the beauty of metal curve with its straight bar automatic turning technology. Teacher Zhou Zhangling said to the author that this inspiration should be considered on the one hand to gather smoke and on the other hand to create a "lightweight" perception.

Figure 2: Martian Integrated Products Q5

However, the value of the color is only reflected in the external, can be achieved at the production level? Liao Qiuyong and his team is undoubtedly a huge challenge, 'such as our product stove panel, the straight line to be very straight, the arc will have to be very soft, It is very difficult to manufacture.If the mold falls into even a hair, a dust, the panel will have a pit, so it is simple and not simple.Liu Qiuyong, for example.

In particular, when the performance of Mars integrated stoves doubled, 100,000 units of products off the assembly line, coincides with the largest year of production.How to design landing, the more in-house products on the appearance, structure, function has an excellent and efficient Scientific management and control process.

In this regard, Martian workshop internal adjustment, from results-oriented, process-oriented from pay attention to the finished product pass rate, to pay more attention to the control process through rate, and process through rate to control more than 90% Inspection, supervision of each person's production process, reduce the rework situation.

The process-oriented assessment by modules is also part of the modernization of the Martian manu- facturing workshop over the past year as a direct result of a 30-40% increase over the entire year , A 50% improvement in quality, which undoubtedly sets a good start for the 2018 goal of 20,000 units per month.

'Lean' traction throughout the year to create the main line

In the final analysis, what is the lean production that Martians uphold?

Is to eliminate waste and continuous improvement as the core, customer demand-driven, so that enterprises with minimal investment costs for the new production management mode.At the same time, a scientific and rational manufacturing system for customers to bring added value and shorten the production cycle, which Significantly improve the ability of enterprises to adapt to the ever-changing market.

Liao Qiuyong told the author that in order to make the products manufactured more secure, first of all, each part of the Martian products is always guaranteed by the mold, so as to ensure that the products are mature in technology and the products are consistent. , Companies invested heavily in the purchase of appropriate equipment, such as 500 tons of frame hydraulic machine, high-power laser welding machine, robot welding machine, etc. Finally, we still continue to learn Toyota production management methods, please come to Toyota's teacher Lecture, held MLPS (Martian Lean Production) start-up meeting, and gradually formed with Martian business characteristics of the front-line management.

Figure 3: MLPS (Martian Lean Production Method) Launched the site

'We are in compliance with the "Made in China 2025" plan put forward by the state. We first standardize the material placement in the workshop, the job flow of each post and the training of employees. On the basis of this, we can standardize the production process, the production process Automation, and finally using the Internet of Things to connect with suppliers and customers to eventually form an intelligent Martian production. "Liao Qiuyong said.

At present, the second phase of Wisdom Cookware Integrated Industrial Park project total investment of 695 million yuan, covers an area of ​​191.7 acres, the new parts shop, assembly plant, warehouse and other factory floor, will be equipped with high precision punching bed, assembly line, automated warehouse And other production design, building a full range of intelligent interactive integrated kitchen Industrial Park.After the completion of the project, with an annual output of 150000 sets of integrated kitchen production capacity.

Figure 4: Martian cookware intelligent integrated industrial park two

The 100,000 off the assembly line is just the beginning. For the rapid growth of Martians, more lean production management will continuously create the ideal product that will provide China's kitchen with a better service experience in line with consumers' needs.