Anyone who has visited car OEMs knows that the assembly line of the car is a streamlined production method. It is sent to a frame at the first station, and the final station comes out through the assembly process of multiple stations in the middle. An entire vehicle enters testing and debugging. So, can auto cover molds be produced in a streamlined production mode? The author believes that the key to whether or not it can be achieved depends on how the mold processing technology creates flowing manufacturing mode and how to create a "one stream" production mode.
Mold Processing Technology and Status Quo
The development of high-level automotive panel molds depends on two major technologies—design technology and manufacturing technology. The design technology mainly includes five aspects, that is, the stamping process technology, digital remanufacturing technology of the cover product, the structural design technology of the mold, the processing technology of the mold and the CAM numerical control programming technology. The manufacturing technology mainly includes the following four aspects: FMC real-type production technology, NC processing technology, mold assembly technology and mold debugging technology.
In recent years, in order to improve the level of mold development and strengthen market competitiveness, domestic mold enterprises have introduced a large number of hardware and software, computer and numerical control processing equipment to increase exponentially. At the same time, they have increased the training of all aspects of skills, and the level of mold development has made a great deal of progress. improvement. However, the mold processing technology that restricts the mold design technology and manufacturing technology is still a weak link in the mold industry, and some companies do not pay enough attention. At present, all manufacturers attach great importance to the stamping process technology, CAM numerical control programming technology, mold structure design technology, manufacturing technology, processing technology, assembly technology and mold debugging technology in the mold design technology, and make great efforts to improve, but the mold The processing technology, but still basically stay in the use of traditional mechanical processing technology prepared to meet the guidance of on-site production level. Deeply consider the role of processing technology, how to guide the workers from the traditional processing, solve the processing problems, to expand the mold production and manufacturing process optimization, production of the balance, the cycle of planning, quality control, production efficiency evaluation , evaluation of capabilities, setting of posts at each link, and matching of human resources, etc. From the above, we deeply feel that the mold processing technology has always been one of the difficulties in improving the mold industry's technical level, quality of adhesion, cycle and efficiency, etc. Key factor.
Digital "One Flow" Production Mode Analysis
The production of molds is a single piece and individual pieces are produced in small batches. The traditional practice is the fitter's responsibility system. In this way, the content of the process is fragmented, and the connection and the overall system are not strong. Therefore, the quality of the mold processing and manufacturing depends on the level of the fitter and the depth of understanding of the design intent. At present, with the development, progress and innovation of technology, people have integrated the design technology and manufacturing technology of the mold into a whole. Through the planning, planning, design, and programming of the technology, each mold forms a complete “digitalâ€. The processing plan is passed to the processing workshop, so that the mold processing and assembly work is getting closer to “building blocksâ€. As long as the order is clearly defined and assembled in sequence, the final assembly results only depend on assembly skills. In other words, the "digital" processing scheme of the technology can completely create the "one stream" production mode of the mold. If the hardware and software resources of the mold industry are in place, it can completely change the current state.
The technology's "digital" processing plan can provide the following manufacturing and assembly conditions: FMC real-type production: rely on "digital" program, full-face numerical control processing, review and confirm, ensure the quality of castings; processing of the casting's structural surface: rely on "digital" program, CNC machining guarantees structural surface accuracy; initial assembly: relying on "digital" program to achieve rapid assembly of screw hole synchronization technology; accuracy of profile and contour clearance: rely on "digital" program, CNC machining to ensure reasonable fit clearance and accuracy; punch and concave Modular installation: rely on "digital" program, punch punch centering hole and embedded type die hole; guide accuracy of upper and lower die base: rely on "digital" program processing guarantee; mold debugging: rely on "digital" CAE simulation analysis guide debugging.
In a word, the quality of assembly and manufacturing of the main function of the mold has been ensured by the work of the fitter who originally depended on the skill, and it has been transformed into a “digital†processing scheme through the technology to guarantee it. As a result, the manual workload of the fitter has become less and less. The skills required may be getting lower and lower, which is another trend in the industry.
Under this trend of development, enterprises that have certain technical human resources and numerical control equipment manufacturing resources can fully optimize the mold manufacturing process and develop in the direction of digital “one-stream†production methods for automobile cover molds.
Production process optimization
Car cover products are similar in shape, and their specific data sizes vary widely. Therefore, the mold structure also has characteristics similar to those of automobile cover products, which are generally similar and the specific structural data varies greatly. However, the “digital†processing solutions for mold design technology are only similarities and are not very different. Much the same is the mold development process and the processing process, which vary greatly from technology's "digital" processing plan data.
The company's production must have a technological process. The technological process must be continuously optimized, improved, and improved with the advancement of technology. After the optimized process is determined, we need to adjust the resources required for configuration according to the various aspects of the process flow.
1. Configuration of production equipment resources
For the allocation of production equipment resources, it is first necessary to analyze which part of the digital “one-stream†production process of the company's mold development is a weak link, which is the bottleneck of “one streamâ€. Mold companies consider the quality, cycle, cost, and efficiency of molds as the bottleneck for the production of "secondary processing" in the eighth link of the top ten links. It is hoped that it will maximize its efficiency. Other links configure the relevant production equipment resources according to the "secondary processing" equipment capabilities, such as: The sixth link "primary processing" mainly configures general mechanical processing equipment and large-scale portal milling machines and planers; the seventh link "initial assembly" mainly configures the days Car, radial drilling machine and fitter assembly, study site; the ninth link "final assembly" is mainly equipped with equipment repair research, assembly and confirmation of the pressure equipment and other equipment.
2. Configuration of human resources
After determining the equipment resources for the development of digital “one-stream†production process according to mold development, the division of detailed production links in each part can be carried out according to the ten major links of the process, and post analysis can be conducted. After the assessment of the workload of each part, the post is set up to match the required skills for different positions. Next, master first-hand data through practice tracking as a basis for evaluation, adjustment, and reconfiguration.
The following principles should be adhered to in the development of the digitized “one-stream†production process configuration human resources with molds:
(1) According to the principle of skill adjustment: The staffing of each link is determined by job analysis, and it is dynamically adjusted with the training of the staff and the improvement of skills in practice;
(2) According to the principle of adjustment of equipment resources: the configuration of personnel in each link will change with the change of production equipment resources, and the performance and efficiency of production equipment will increase, and personnel can adjust downwards;
(3) According to the principle of adjustment of process changes: the staffing of each link, with the optimization, simplification and efficiency of the processing process, personnel can adjust downwards;
(4) The principle of maximum efficiency: "One flow" production, insisting on the principle of matching each link's ability to maximize efficiency and pursue maximum efficiency.
Production plan customization
The assembly line of the automobile adopts a streamlined production method, and the digital flow of the mold “one stream†is also the pursuit of such an effect. When the capacity of human resources and processing and assembly resources of the eighth largest link in our “one flow†production are in place, it can be said in principle that the “secondary processing†capability of CNC milling each month is the ability of a company to produce molds monthly. As long as the number of workdays for each of the six major links after each mold is given by actual manufacturing conditions, then the molds that are put into "one-time processing" today can be predicted when the "downline" is to be adjusted, and if the intermediate plan is properly controlled, it can be It is foreseen to which extent the processing and assembly of the mold are currently in the process. Of course, in order to ensure the balance of "one stream" production and to cope with the anomalies that occur in the manufacturing process, we can reserve one or a half CNC machining capacity in the "secondary processing" of the eighth link, not counting " A flow "production plan preparation, call at any time.
The goal of the production process
The aim of the digital "one-stream" production of molds is the same streamlined production mode as the automobile assembly line. The premise of realizing digital “one stream†production is the standardization of the processing technology. The goal of standardization is to realize digitization of the processing technology and output each die digital processing technology program. On the basis of clearing the system processing process flow, it is necessary to guide how a single piece is processed and assembled, and a digital program-driven operation is required to solve the processing technology. Sexual issues. The digital processing standard of moulds shall reflect the specialization of the mould manufacturing of enterprises and realize the “one-stream†production process. In theory, it shall fully satisfy the requirements of the quality characteristics of the mould. In practice, it shall have flexible operation, while ensuring the quality. Pursuing efficiency maximization.
Conclusion
The realization of the "one-flow" production process for the digital standard machining process of the mold is the development direction of the mold industry and reflects the characteristics of modern mold processing methods. In short, as long as we grasp the match between human resources and equipment resources, and follow the digital “one-stream†production method, optimize the processing scheme and standardize the production process, the planning can be accurate, and the production surplus capacity can be accurately grasped. In order to maximize the control and improvement of the cycle, cost and efficiency, the assembly line of the automobile assembly line can only be realized in the mold factory.
Mold Processing Technology and Status Quo
The development of high-level automotive panel molds depends on two major technologies—design technology and manufacturing technology. The design technology mainly includes five aspects, that is, the stamping process technology, digital remanufacturing technology of the cover product, the structural design technology of the mold, the processing technology of the mold and the CAM numerical control programming technology. The manufacturing technology mainly includes the following four aspects: FMC real-type production technology, NC processing technology, mold assembly technology and mold debugging technology.
In recent years, in order to improve the level of mold development and strengthen market competitiveness, domestic mold enterprises have introduced a large number of hardware and software, computer and numerical control processing equipment to increase exponentially. At the same time, they have increased the training of all aspects of skills, and the level of mold development has made a great deal of progress. improvement. However, the mold processing technology that restricts the mold design technology and manufacturing technology is still a weak link in the mold industry, and some companies do not pay enough attention. At present, all manufacturers attach great importance to the stamping process technology, CAM numerical control programming technology, mold structure design technology, manufacturing technology, processing technology, assembly technology and mold debugging technology in the mold design technology, and make great efforts to improve, but the mold The processing technology, but still basically stay in the use of traditional mechanical processing technology prepared to meet the guidance of on-site production level. Deeply consider the role of processing technology, how to guide the workers from the traditional processing, solve the processing problems, to expand the mold production and manufacturing process optimization, production of the balance, the cycle of planning, quality control, production efficiency evaluation , evaluation of capabilities, setting of posts at each link, and matching of human resources, etc. From the above, we deeply feel that the mold processing technology has always been one of the difficulties in improving the mold industry's technical level, quality of adhesion, cycle and efficiency, etc. Key factor.
Digital "One Flow" Production Mode Analysis
The production of molds is a single piece and individual pieces are produced in small batches. The traditional practice is the fitter's responsibility system. In this way, the content of the process is fragmented, and the connection and the overall system are not strong. Therefore, the quality of the mold processing and manufacturing depends on the level of the fitter and the depth of understanding of the design intent. At present, with the development, progress and innovation of technology, people have integrated the design technology and manufacturing technology of the mold into a whole. Through the planning, planning, design, and programming of the technology, each mold forms a complete “digitalâ€. The processing plan is passed to the processing workshop, so that the mold processing and assembly work is getting closer to “building blocksâ€. As long as the order is clearly defined and assembled in sequence, the final assembly results only depend on assembly skills. In other words, the "digital" processing scheme of the technology can completely create the "one stream" production mode of the mold. If the hardware and software resources of the mold industry are in place, it can completely change the current state.
The technology's "digital" processing plan can provide the following manufacturing and assembly conditions: FMC real-type production: rely on "digital" program, full-face numerical control processing, review and confirm, ensure the quality of castings; processing of the casting's structural surface: rely on "digital" program, CNC machining guarantees structural surface accuracy; initial assembly: relying on "digital" program to achieve rapid assembly of screw hole synchronization technology; accuracy of profile and contour clearance: rely on "digital" program, CNC machining to ensure reasonable fit clearance and accuracy; punch and concave Modular installation: rely on "digital" program, punch punch centering hole and embedded type die hole; guide accuracy of upper and lower die base: rely on "digital" program processing guarantee; mold debugging: rely on "digital" CAE simulation analysis guide debugging.
In a word, the quality of assembly and manufacturing of the main function of the mold has been ensured by the work of the fitter who originally depended on the skill, and it has been transformed into a “digital†processing scheme through the technology to guarantee it. As a result, the manual workload of the fitter has become less and less. The skills required may be getting lower and lower, which is another trend in the industry.
Under this trend of development, enterprises that have certain technical human resources and numerical control equipment manufacturing resources can fully optimize the mold manufacturing process and develop in the direction of digital “one-stream†production methods for automobile cover molds.
Production process optimization
Car cover products are similar in shape, and their specific data sizes vary widely. Therefore, the mold structure also has characteristics similar to those of automobile cover products, which are generally similar and the specific structural data varies greatly. However, the “digital†processing solutions for mold design technology are only similarities and are not very different. Much the same is the mold development process and the processing process, which vary greatly from technology's "digital" processing plan data.
Figure 1 Top 10 Processes for Optimization of Mold Development Process
Figure 2 Once processing
Fig. 3 Secondary processing
Figure 4 Mold Development Final Assembly
The company's production must have a technological process. The technological process must be continuously optimized, improved, and improved with the advancement of technology. After the optimized process is determined, we need to adjust the resources required for configuration according to the various aspects of the process flow.
1. Configuration of production equipment resources
For the allocation of production equipment resources, it is first necessary to analyze which part of the digital “one-stream†production process of the company's mold development is a weak link, which is the bottleneck of “one streamâ€. Mold companies consider the quality, cycle, cost, and efficiency of molds as the bottleneck for the production of "secondary processing" in the eighth link of the top ten links. It is hoped that it will maximize its efficiency. Other links configure the relevant production equipment resources according to the "secondary processing" equipment capabilities, such as: The sixth link "primary processing" mainly configures general mechanical processing equipment and large-scale portal milling machines and planers; the seventh link "initial assembly" mainly configures the days Car, radial drilling machine and fitter assembly, study site; the ninth link "final assembly" is mainly equipped with equipment repair research, assembly and confirmation of the pressure equipment and other equipment.
2. Configuration of human resources
After determining the equipment resources for the development of digital “one-stream†production process according to mold development, the division of detailed production links in each part can be carried out according to the ten major links of the process, and post analysis can be conducted. After the assessment of the workload of each part, the post is set up to match the required skills for different positions. Next, master first-hand data through practice tracking as a basis for evaluation, adjustment, and reconfiguration.
The following principles should be adhered to in the development of the digitized “one-stream†production process configuration human resources with molds:
(1) According to the principle of skill adjustment: The staffing of each link is determined by job analysis, and it is dynamically adjusted with the training of the staff and the improvement of skills in practice;
(2) According to the principle of adjustment of equipment resources: the configuration of personnel in each link will change with the change of production equipment resources, and the performance and efficiency of production equipment will increase, and personnel can adjust downwards;
(3) According to the principle of adjustment of process changes: the staffing of each link, with the optimization, simplification and efficiency of the processing process, personnel can adjust downwards;
(4) The principle of maximum efficiency: "One flow" production, insisting on the principle of matching each link's ability to maximize efficiency and pursue maximum efficiency.
Production plan customization
The assembly line of the automobile adopts a streamlined production method, and the digital flow of the mold “one stream†is also the pursuit of such an effect. When the capacity of human resources and processing and assembly resources of the eighth largest link in our “one flow†production are in place, it can be said in principle that the “secondary processing†capability of CNC milling each month is the ability of a company to produce molds monthly. As long as the number of workdays for each of the six major links after each mold is given by actual manufacturing conditions, then the molds that are put into "one-time processing" today can be predicted when the "downline" is to be adjusted, and if the intermediate plan is properly controlled, it can be It is foreseen to which extent the processing and assembly of the mold are currently in the process. Of course, in order to ensure the balance of "one stream" production and to cope with the anomalies that occur in the manufacturing process, we can reserve one or a half CNC machining capacity in the "secondary processing" of the eighth link, not counting " A flow "production plan preparation, call at any time.
The goal of the production process
The aim of the digital "one-stream" production of molds is the same streamlined production mode as the automobile assembly line. The premise of realizing digital “one stream†production is the standardization of the processing technology. The goal of standardization is to realize digitization of the processing technology and output each die digital processing technology program. On the basis of clearing the system processing process flow, it is necessary to guide how a single piece is processed and assembled, and a digital program-driven operation is required to solve the processing technology. Sexual issues. The digital processing standard of moulds shall reflect the specialization of the mould manufacturing of enterprises and realize the “one-stream†production process. In theory, it shall fully satisfy the requirements of the quality characteristics of the mould. In practice, it shall have flexible operation, while ensuring the quality. Pursuing efficiency maximization.
Conclusion
The realization of the "one-flow" production process for the digital standard machining process of the mold is the development direction of the mold industry and reflects the characteristics of modern mold processing methods. In short, as long as we grasp the match between human resources and equipment resources, and follow the digital “one-stream†production method, optimize the processing scheme and standardize the production process, the planning can be accurate, and the production surplus capacity can be accurately grasped. In order to maximize the control and improvement of the cycle, cost and efficiency, the assembly line of the automobile assembly line can only be realized in the mold factory.
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