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Production line process optimization helps enterprises reduce costs and improve efficiency.

2023-08-29

The digital and intelligent engineering initiative of Wanxiang Qianchao continues to advance steadily. As one of the key approaches to improving efficiency and boosting profitability, production line process optimization is being steadily promoted. The Wanxiang Qianchao Digital and Intelligent Innovation Center, in collaboration with production and operations teams from various factories, has conducted multiple on-site visits and discussions, jointly formulating 100 digital and intelligent engineering initiatives aimed at process optimization. To date, 28 of these initiatives have been completed. These process optimization initiatives are directly linked to two KPI indicators—material consumption per ten thousand yuan of output value and direct labor productivity—managed by each company’s production and operations centers. Successfully implementing these initiatives will help achieve the targeted KPIs.

Key dimensions for process optimization: First, in the forging process, measures such as optimizing die design and switching from flat forging to vertical forging are implemented to improve material utilization, reduce flash on forgings, and enhance forging quality. Second, in the turning process, measures including process integration, introduction of new cutting tools, and optimization of machining steps are adopted to reduce the number of operations and boost efficiency. Third, in the grinding process, measures such as optimizing stock allowances, eliminating idle travel, introducing new grinding wheels, and substituting turning for grinding help shorten the product’s production cycle time. Fourth, in the heat treatment process, measures like switching from rotary hearth furnaces to salt-bath furnaces for thin-walled bearing components and optimizing quenching parameters are employed to reduce product deformation and eliminate the need for finish turning. Fifth, in the welding process, adjustments to procedures and optimization of fixtures and tooling reduce the number of weld seams, improve welding quality, and minimize the need for rework. Sixth, in the blanking process, adjustments to pipe-cutting and material-layout strategies enhance material utilization.

The Qianchao Senwei Digital Intelligence Engineering Team established a process optimization group to address the issue of high tool consumption and low production efficiency in the machining lines—including the DL382 flange shaft line, PQ flange shaft line, and Changcheng shaft line—in the precision machining workshop. This issue was caused by unstable tool life. The team conducted a comprehensive analysis of the service life of various types of tools, such as turning tools, milling cutters, slotting tools, and drills, and identified 10 tool models for which new prototypes were introduced. After three months of multiple rounds of prototype testing, seven of these new tool models ultimately met the expected performance targets. As a result, both tool life and the number of times tools needed sharpening improved significantly, and the overall per-piece cost of tools decreased by 30%.

Qianchao Senwei’s Li Mingming said: “Qianchao Senwei produces basic components, and our annual expenditure on consumables is extremely high—among which tool consumption accounts for around 10 million yuan. Therefore, reducing consumable usage through process optimization initiatives is particularly important for Qianchao Senwei. This year, under the Digital Intelligence Engineering initiative, we’ve implemented five major initiatives and 26 sub-initiatives aimed at cutting consumable usage. All these initiatives have been meticulously documented, with clearly defined milestones, specific action items, responsible persons, and timeframes. This comprehensive, day-by-day, week-by-week, and month-by-month project management approach ensures that we can track progress throughout the entire implementation cycle, thereby guaranteeing the achievement of our initiative’s effectiveness goals and the realization of our objective of refined management.”

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