First, sprout: Ford Motor car assembly line production

In 1913, Ford Motor Company was the first to establish the assembly line automobile assembly system, which triggered an earth-shaking revolution in the world automobile manufacturing industry and promoted the scale of automobile production. Ford's assembly line has one station for each task, which means hundreds of cars running through the plant can be produced simultaneously.

In Ford's original factory, the Ford T model is assembled in 93 minutes. In fact, every three minutes, a whole car rolls off the line. This was the beginning and embryonic stage of the automobile production line, and at the same time, this stage made cars no longer the exclusive exclusive of the rich, and millions of ordinary people could also afford to drive their own cars.

Second, innovation: Japan's "just-in-time production system" JIT production mode

In 1953, Daiichi Ohno, vice president of Toyota, Japan, integrated the characteristics and advantages of single-piece production (one-piece-flow) and mass production, and created a high-quality, low-consumption production mode under the conditions of multi-variety and small-batch mixed production, namely Just In Time (JIT).

Just-in-time production (JIT), also known as stockless production, means that the necessary parts are sent to the production line In the necessary quantity at the necessary Time. And only the parts that are needed, only in the quantity that is needed, and only at the time that is needed are sent to production. Therefore, the starting point of just-in-time production system is to continuously eliminate waste, reduce inventory, and carry out continuous circular improvement.

The basic idea of JIT production is "only when needed, according to the amount needed, to produce the required product", that is, the pursuit of a production system with no inventory or minimum inventory. The basic idea of JIT is production planning and control and inventory management. Therefore, JIT production mode is also called "lean production".

Third, development: automated workshops and factories

After the 1950s, automated semi-automated assembly lines began to appear, which were called rigid automatic lines. In particular, the development of electronic computers and automatic control technology has greatly promoted the automation of the production process.

In the 1960s, industrial production began to use electronic computers for optimal control of large equipment, such as large distillation towers and large rolling mills, and realized direct digital control (DDC) and set point control (SPC).

From the 1970s to the 1990s, the development of automated instruments and hardware and the advent of microcomputers have brought the automation of the production process into a new high-level stage. The central control of the whole factory or the whole process, the application of computer systems for multi-parameter comprehensive control, or the use of multiple computers for hierarchical comprehensive control of the production process and participation in management and management, is the main feature of this stage.

Since entering the 21st century, the concept of "people-oriented" and "energy saving and environmental protection" has been deeply rooted in the hearts of the people, and factory automation is developing into comprehensive factory automation (also known as total automation). According to the survey and analysis of the American Academy of Sciences, the automobile factory adopts whole-plant integrated control, the product quality is improved by 2-5 times, the production efficiency is increased by 40-70%, the equipment utilization rate is 2-3 times, the production cycle is reduced by 30 to 60%, and the working capacity of engineers is increased by 3-5 times.

4. Transformation: Intelligent manufacturing in the era of Industry 4.0

Today, mankind ushered in the era of Industry 4.0, the Internet of Things and manufacturing services ushered in the "Industry 4.0" led by intelligent manufacturing, which aims to make full use of information and communication technology and cyberspace virtual system - information physical system combination means, the manufacturing industry to intelligent transformation.

The automotive industry, as a representative of the higher degree of intelligence in the manufacturing industry, has taken the lead in testing water industry 4.0, including Mercedes-Benz, BMW Group, Volkswagen Group and Bosch. In China, companies engaged in automobile manufacturing have also begun to think about the transformation of the 4.0 era, and the Dongfeng Nissan factory, for example, has become a pioneer in the era of "Industry 4.0". In 2017, Dongfeng Nissan fully implemented "i? Plan ", its "intelligent quality" is through the intelligent upgrade of manufacturing technology, factory automation transformation, the construction of advanced engineering technology center, digital development platform, intelligent seiko manufacturing and information quality management, to "intelligent" quality. Such as:

1. Comprehensively improve factory automation to ensure high-quality product output

In 2016, Dongfeng Nissan four places and five plants fully introduced new flexible and intensive automatic production lines, which can realize the ordning-type production of the whole vehicle series, reduce the floor area by 30% to 50%, reduce the vehicle and parts in the library by 20%, and the automation rate will continue to increase in the next three years. For example, stamping technology, welding workshop, painting workshop, resin workshop, etc., are fully applying advanced automation technology.

In terms of final assembly, new technology projects such as instrument panel automatic assembly, engine & gearbox automatic assembly, and new robot applications have also completed the preliminary development, among which the newly introduced automatic rim coating, automatic sorting of fuel tanks and other automation improvement projects have been launched, so that the automation rate has increased to 12.5%(the average automation rate in the industry is 7-8%). In the industry's leading level.

2. Use forward-looking intelligent technology to incorporate technology into the core of the product

In terms of forward-looking intelligent technology, Dongfeng Nissan put into use the first "integrated system" advanced engineering Technology center (AEP) in China in 2016. The newly completed AEP will undertake the three functions of creating a new intelligent green factory, product concurrent development, system construction and expert talent cultivation, and provide three intelligent means of digital development platform, intelligent seiko intelligent manufacturing tools, and big data quality management. Its highlight technologies include VR virtual evaluation technology, 3D printing rapid prototyping, green friendly robots, laser online measurement, machine perception and iot, blue light scanning, ultrasonic welding spot detection, and continue to improve the quality of intelligent manufacturing.

3. The whole intelligent monitoring system realizes automatic early warning of the production line

In terms of quality control, Dongfeng Nissan engine factory uses the concept of intelligent manufacturing. The whole system assigns identity cards to each product, automatically collects data of each project, and connects relevant information through the unique identity, finally forming the data of the full track. The accurate collection of data expands unlimited possibilities for the application of data. Products, equipment, production lines, models and other dimensions can be accurately tracked, and automatic early warning of the production line can be realized to prevent the outflow of defective products.

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