"stop the line" once and keep the bottom line of 3 million value
Late at night in midsummer, our five-axis machining center is processing the humanoid robot harmonic reducer rigid wheel at full speed, this batch of core components with a total price of 3 million, and there are only 3 days left in the countdown to delivery.
The MES system suddenly popped up a yellow warning: the tooth shape deviation of the ring in the 137th product increased in the same direction for 3 consecutive pieces, and the upper limit of tolerance was reached by 70%. Without the slightest hesitation, the operator decisively pressed the red stop button.
"The company's iron law: if there is a bad trend in the same direction for 3 consecutive pieces, the line must be stopped immediately, and the defective parts must not be allowed to flow into the next process." The operator's determination stems from the rules engraved in the process.
The engineer found that the remaining life of the tool was 15%, but the spindle vibration quietly rose by 0.002mm within half an hour, and it was this small deviation of 2 microns that caused the accumulation of deviation. After replacing the tool and spindle compensation, it was delayed for only 2 hours, but the entire batch was scrapped.
Customer feedback: If defective parts flow into the assembly line, the rework cost of the whole machine is 20 times the value of the parts, and this interception directly avoids millions of potential losses.
Good management is never to eliminate problems, but to accurately intercept and completely solve defects before they become waste.
A set of hardcore data
How extreme our management is
This is not an accidental exception, but a daily standard in our factory. In the past 12 months, the real data of the three core business segments bears witness to the hard core power of "stupid management":
The secret of zero customer complaints for 8 consecutive months of medical device parts is hidden in the ultimate details: the cutting fluid concentration, cleaning water temperature, and packaging cleanliness of each implant-grade part are automatically collected by the MES system throughout the process, and the data can be archived for 15 years.
Extreme challenge
Winning the "impossible mission" of the aerospace customer
Last year, we undertook an emergency order for a certain type of engine valve body in aerospace, and the three major problems can be called the limit of the industry
1. Extremely difficult materials to process:superalloy GH4169, high hardness, easy to stick knives, extremely high requirements for tools and processes;
2. Tolerance Breaking Limit:8mm deep hole tolerance ±0.005mm, equivalent to 1/10th of the diameter of a hair;
3. Delivery time is reduced by more than half:regular 45 days delivery, customer requirements 25 days to complete.
Our full-process management system calmly solves extreme challenges:
1. Day 1: Process locking:Start AS9100 configuration management, confirm drawing versions, inspection standards, and special processes with customers, and sign and lock to eliminate later change disputes.
2. Day 3 ・Equipment Selection:TPM full maintenance inspection found that the Z-axis repeated positioning accuracy of the original machine fluctuated by 0.003mm, and although it was within the tolerance, it was still possible to replace the equipment accurately compensated by the laser interferometer, and it would be better to spend half a day more to eliminate hidden accuracy hazards.
3. Day 5 - Tool control:Customized special coating hardening drill bits, the system sets the tool life to 80 pieces, processing to 65 pieces automatic warning, and 80 pieces forced tool change. Measured verification: after 85 pieces, the aperture must be exceeded, and the system understands the process limit better than manual labor.
4. Day 15 - Process monitoring:After the first piece is qualified, the MES implements real-time SPC monitoring of the deep hole size, and the CPK of the 42nd piece is reduced from 1.45 to 1.21, and the system automatically warns of abnormal coolant concentration, and the CPK rises to 1.52 after adjustment
5. Day 24 ・Perfect delivery:Delivered 1 day in advance, fully inspected, received with zero concessions.
The real management system is not the rules that bind hands and feet, but the confidence to cope with extreme challenges. We can overcome problems that others can't do, just because the process can be early warning and scientific problem-solving.
Essential differences
Why the traditional "first and final inspection"
Not as good as system-level immunity?
Most factories have first, patrol, and final inspections, but why can we achieve the ultimate yield rate of 99.99%? The core is to engage in post-remediation and upgrade the thinking of the whole process of immunization.
Traditional manufacturing model (passive control)
First inspection:a single piece is qualified to start construction, and the benchmark risk is difficult to control;
Inspection:random inspection every 2 hours, nearly 2 hours in the middle are all control blind spots;
Final inspection:The finished product is detected as a waste product, and the materials, working hours, and electricity costs are all sunk, and the loss is irreversible.
Our closed-loop model (active immunization)
Take 200 pieces of medical precision parts as an example:
First inspection:cross-checking with double measuring tools, locking the reference in 15 minutes to eliminate errors from the source;
Process:MES collects the key dimensions of each piece without stopping, the data fluctuation of the 15th piece exceeds the threshold, and the detection frequency is automatically encrypted.
Warning:The trend of item 18 is abnormal, the system automatically forcibly stops the line, and the investigation finds 0.005mm chip residue on the positioning surface (which cannot be recognized by the human eye), and resumes production after rapid removal.
Final inspection:100% monitoring of the process, final inspection only needs sampling inspection and appearance verification, the yield rate of the whole batch is 99.5%, and the only waste product is the original defect of raw materials, which is not caused by processing.
Data comparison:The scrap rate of the traditional model is 3%-5%, we are only 0.5%, and the cost of a single batch is 25,000 yuan.
More core value:ensuring zero stop of customer assembly lines, which is the real cost reduction and efficiency increase.
The truth of the five certificates
The iron law in the process
We holdfive international certifications: ISO 9001, AS9100, IATF 16949, ISO 45001, and ISO 14001, and the value of the certificate is never in the display, but in the implementation of every operation detail.
AS9100 (aerospace):forging configuration management ability, when the customer's drawing version is changed, the system automatically compares and locks the old version, the operator cannot retrieve it, completely eliminating the risk of wrong use of drawings;
IATF 16949 (Automotive): Failure analysis of the PFMEA process, after predicting the risk of misuse of the gauge, the color of the workstation and the gage is error-proof, and the error is perceived, and there is zero error from then on;
ISO 45001 (Safety):Adhere to the principle of safety first, the voltage is unstable during typhoons, and the precision process is automatically suspended, preferably postponed for 2 days without damaging the accuracy of the equipment and burying quality hazards.
Why can we do a good job in the three high-precision fields of aerospace, medical and robotics? It is not relying on a certain master or stacking expensive equipment, but a replicable, landable, and combat-proven zero-defect management system
(1) 6S management, so that the site is as clean and controllable as an operating room;
(2) ERP+MES linkage, each part has a full life cycle digital file;
(3) Upgrade the first and final inspection to realize SPC real-time early warning + the right of all employees to stop the line;
(4) The five major certifications are the skeleton, and the details are controlled as flesh and blood;
(5) All actions should be dealt with quickly when the problem is in the bud.
What we sell to customers is never a single part, but a zero-defect guarantee that has been rigorously verified by the aerospace, medical, and robotics industries, which is the strongest moat of precision manufacturing.
Welcome to visit the factory, you will not only see high-precision equipment, but also a well-trained team, and a set of self-breathing, continuous iteration of the living management system.
