Compared with before the transformation, the production capacity of factory No. 18 increased by 123% and the personnel efficiency increased by 98%. Photo by Jiang Lian
Industry and Economic Weekly (Reporter Wang Fan, Ou Yaqi) On October 11, the World Economic Forum (WEF) announced the latest batch of "Lighthouse Factory" list, with a total of 11 companies selected and 5 from China. Among them, Sany Heavy Industry Factory No. 18 located in Changsha Economic and Technological Development Zone was successfully selected.
In order to cope with the challenges of cyclical fluctuations in the heavy industry market, the challenges of multi-variety small batches (263 categories) and heavy-duty component production, Factory No. 18 has made full use of flexible automated production, artificial intelligence and large-scale IIoT to establish a digital and flexible heavy-duty equipment manufacturing system. In the end, the factory production capacity was expanded by 123%, the productivity was increased by 98%, and the unit manufacturing cost was reduced by 29%.
The McKinsey Lighthouse Factory expert group, which conducted a field visit to Factory No. 18 in the early stage, unanimously agreed that Factory No. 18, in the most difficult field, has opened up core technologies with creative thinking without any precedent, which is very commendable.
18 factory covers an area of 100,000 square meters. It is the first batch of intelligent manufacturing pilot demonstration factories of the Ministry of Industry and Information Technology. It is praised by " Wall Street Journal " as "the blueprint of China's future industry is hidden here." The global market share of pump trucks, tow pumps, , and on-board pumps produced by Factory No. 18 has been ranked first in the world for many years, helping Sany Heavy Industry to become the veritable "world pump king".
is based on the tree root Internet industrial Internet platform. At present, all 9 major processes and 32 typical scenarios of Factory No. 18 have achieved "smart operation". , director, executive president and chief engineer of , Sany Group, , Yi Xiaogang, , said: "Everything that computers can do, no one is allowed to do."
In factory No. 18, each pump truck has an exclusive "id card" starting from the raw materials, which is intelligently dispatched by MOM's "factory brain" to realize the implementation of all elements of intelligent manufacturing "one steel plate in, one pump truck out".
1540 sensors and 200 fully connected robots in the factory can generate more than 30TB of big data every day, which is equivalent to the mobile network traffic generated in a county with a population of 200,000 in one day. The cutting and sorting of
steel plates are completely handed over to the AI robot with 3D vision, which increases the accuracy to 1 mm while shortening the cycle by 60%, and reducing material waste by nearly half. Workers were basically missing in the welding center where sparks were splashing. Relying on arc tracking technology, the 3.7-meter-long and 2.6-ton pump truck turntable has achieved "fixless gripping and welding" for the first time in the industry. In the assembly center, the professional skills possessed by Sany "masters" are parameterized and software-turned into robot programs, as large as 70-meter-long booms and as small as 2-centimeter-screws, etc., are automatically assembled, and the efficiency is exponentially improved. The machine-added center that can mix and produce 163 types of valve blocks is a demonstration unit for factory "light-off" flexible production. Empowered by digital twin technology, Sany Quality's original accuracy error of only 0.1 mm was refreshed to the 10 micron level. The end-to-end logistics system can realize the automatic handling and loading and unloading of 101,320 different types of parts, and the on-time delivery rate of is as high as 99.2%, making it the "capillary" for the efficient operation of the lighthouse factory.
Intelligent manufacturing brings a leap in production efficiency. Compared with before the transformation, the production capacity of Factory No. 18 increased by 123%, the personnel efficiency increased by 98%, the overall automation rate increased to 76%, and up to 263 models can be produced.
In 2021, the per capita output value of Factory No. 18 was 14.7113 million yuan, with a profit of 154,000 yuan per square meter. Both core data are the "beacon benchmark" of the global heavy industry industry.
It is understood that Sany Heavy Industry Factory No. 18 Changsha is the second company in Hunan to be listed as the "Lighthouse Factory".
In March this year, World Economic Forum announced the list of the first batch of 13 "lighthouse factories" in 2022. Bosch Auto Parts (Changsha) Co., Ltd. was selected and became the first intelligent manufacturing factory in Hunan Province to be awarded the title of "Lighthouse Factory". Both factories are located in Changsha Economic and Technological Development Zone.
At present, Bosch Changsha is a provincial, municipal and district intelligent manufacturing demonstration enterprise. It has been approved as one of the first ten "5G+Industrial Internet Demonstration Factory" released by the Provincial Department of Industry and Information Technology. It has a provincial industrial Internet big data platform and various artificial intelligence solutions, and is applied in multiple links of production and operation.
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