Shulou(Shulou.com)11/24 Report--

Interviewee: ideal manufacturing team

Author: sun Wei

Abstract: release is listed, listing is quantity, and quantity is high quality

Introduction:

On average, one car can be built every 40 seconds, 90 new cars per hour are off the production line, and the daily output reaches 1800. This is the ideal car manufacturing base in Changzhou. It is this ideal manufacturing speed that supports the ideal car to become the first Chinese new power car company to reach a cumulative delivery volume of 500000 vehicles.

You can find the echo and answer on Li Xiang's Weibo six months ago.

"Manufacturing and products are a community with a shared future! From the first day of its establishment, ideal Automobile decided to build its own factory (purchase production qualification) and control the whole manufacturing process. Since the construction of the booster factory and the five-in-one powertrain plant in 2020, a base in Changzhou will generate more than 100 billion in revenue by 2023. It is precisely because of the continuous investment in manufacturing that both efficiency and quality are reflected in the leading sales at the same level and at the same price. "

"release is listed, listing is quantity, high quality is high quality", high-quality fast delivery has brought more users' recognition of the brand, this is the ideal manufacturing speed, unique in the industry, become the industry leader. This is not only based on the execution of the mission of the ideal manufacturing team, but also the inevitable result of the upgrading of the ideal manufacturing system in 2023-an ideal manufacturing system that can meet the higher market demand, comprehensively increase production capacity and ensure quality and quantity.

Let's take a look at how the ideal manufacturing upgrade in 2023 will support the ideal to become the number one new power in China.

1. IT empowers lean production and establishes a manufacturing "moat"

The ideal automobile Beijing base, located in the north of Shuanghe Street, covers an area of 786 mu, and has built four major workshops: stamping, welding, painting and final assembly, all of which adopt international advanced, environmentally friendly and efficient production technology. at the same time, based on digital twin technology, we focus on building an ideal flagship factory in intelligent manufacturing. Ideal MEGA, the first pure electric model of ideal car, which has attracted a lot of attention, will be offline here. This is the second modern intelligent manufacturing base for ideal cars to be put into production soon after Changzhou base.

Changzhou manufacturing base, located in Wujin District, Changzhou, carries the production task of ideal first product ideal ONE and ideal L-series models, and puts "smart" manufacturing in a key position at the beginning of construction.

Self-developed visual AI algorithm to create the first unmanned detection line in the industry, realizing 100% unmanned inspection of key processes such as chassis inspection, fast and slow charge inspection. Lianshan system breaks through the "information isolated island" in traditional automobile manufacturing, and uses big data model and basic correlation analysis algorithm to realize intelligent early warning of production quality, which can not only predict the prevention problems in advance, but also make the lean mode of production evolve faster. Self-developed intelligent manufacturing operating system Li-MOS is a system that integrates cutting-edge technologies such as big data, cloud computing and artificial intelligence, from order generation to parts pull, from vehicle production scheduling to vehicle shipment, to full-dimensional intelligent information management to create a "super brain" of the factory.

Li Bin, head of ideal automobile manufacturing, said, "the ideal self-developed Li-MOS and the process quality monitoring system Lianshan are the best practices of IT enabling manufacturing, and the current operation is quite efficient."

Li Bin believes that in the era of traditional automobile manufacturing, TPS (Toyota Lean production) has always been the benchmark of the industry, leading the world. It is also an example for the automobile manufacturing industry to learn from. In today's digital intelligent enabling manufacturing, lean production is still the foundation, such as standardization, improvement, five principles, seven kinds of waste, eight steps, ten basic consciousness, etc., are still the basic skills and the cornerstone of manufacturing.

"however, facing the increasingly competitive automobile manufacturing in the future, if we want to take a substantial lead in the direction of quality Quality, cost Cost, delivery Delivery and so on, it is not enough to stick to lean production to form a manufacturing 'moat'." Li Bin believes that automated, digital and even intelligent IT and AI technologies must be given to lean production in order to be more powerful and superior in QCD.

In terms of hardware intelligence, 100% welding automation has been realized in Beijing and Changzhou bases; on the final assembly production line, many steps such as tail doors, tires, skylights and so on are automatically installed. " We use automatic assembly robots instead of traditional manual assembly, a large number of visual perception robots automatically take pictures, judge, and then realize job assembly according to algorithms, and finally identify unstable anomalies and defects through visual inspection. and take measures to prevent the problem from flowing to the next job. " Brother Lei, the person in charge of Beijing base, said.

One of the important benefits of intelligence and automation is to maintain the stability of product manufacturing quality. "even an old master with particularly good skills may make mistakes. And the robot can maintain stability, just like an old master who will never make mistakes." Brother Basi said.

In order to pursue better quality and efficiency, we have been iteratively optimizing the production line development. The ideal manufacturing team and the R & D ME team (Manufacturing Engineering, Manufacturing Engineering) join hands to upgrade the new production line development and manage the production line as a product throughout the life cycle.

On the ideal L series production line, we realize the monitoring of all the key process quality parameters of the production line through the Lianshan process quality monitoring platform, ensuring the high-quality delivery of each product produced. In the future, we will upgrade the Lianshan monitoring platform, increase the monitoring of the key parameters of the key equipment of the production line itself, and achieve early warning of the equipment (such as early warning of elevator failure) through big data and AI algorithms, just like the Eye of God is monitoring and warning each device in real time. " This is the same as our logic of making products, and this advantage is that the mobility of the production line in each workshop will become higher and higher, achieving higher vehicle production efficiency. " Meng Jun was previously the leader of the ideal automobile ME team. After the field of work was changed to the head of the manufacturing base, he had a deeper understanding of the necessity of the production line.

In terms of welding, assembly and final assembly logistics, Beijing and Changzhou bases have realized AGV (automatic guided handling vehicle) automatic transport without manual handling or manual driving of tractors, said Rafael, head of manufacturing logistics.

In terms of software intelligence, we not only achieve comprehensive online management, the system will also remind the person in charge of the relevant nodes when and what should be done. In addition, all teams can share real-time view information and follow up status. In many traditional automobile manufacturing departments, the review and implementation of documents still rely on offline paper or online documents, Excel forms to promote management.

‎ 's deeper software intelligence enables production and manufacturing, and let's talk about the ideal car's self-developed Lianshan system, which examines various parameters of the production process in detail, such as the independent coding of each part, whether it is qualified, whether the solder joint is in place, whether there are repair parts, and so on. Every piece of data of each car can be accurately traced back to the source. " The traditional enterprise intelligent software is through the result monitoring, for example, it will also collect the tightening data of the bolts, but the Lianshan system will judge whether there is something wrong with the bolts in the process by monitoring the curve of the torque. our control will be stricter, more comprehensive and more thorough. " Brother Basi said.

Lao Fan, head of production at Changzhou Base, has worked in Japanese enterprises for many years and is familiar with the concept and practice of lean production. He added his understanding: "in the intelligent age, digital production is a blessing to lean production, and IT empowerment will make us jump higher and run faster. But the premise is that the offline business logic and granularity must be clear in order to achieve the online intelligent system closed loop."

Ideal car is still in the process of standardizing factory construction, and we will turn the standard factory buildings and standard production lines of the four major processes of punching, welding, painting and total into replicable "model rooms", "including auxiliary rooms, teams, IT, and logistics. In the past, it took two years from the establishment of the project to the vehicle SOP stage (Start Of Production starts mass production), but in the future we may only need one year to achieve it, greatly accelerating the speed at which the ideal car responds to market demand."

In the future, we will also develop centralized warehousing management systems and maintenance systems, and even look forward to the automatic production of the whole assembly line, with no intervention, no one on duty, raw materials in, and finished products out. The 100% automated "black light factory" on the assembly line will also be realized in the ideal car.

Second, horizontal coordination departments enable large-scale manufacturing, and the management model is upgraded in an all-round way.

Since 2023, the ideal car has been facing the goal of 1.6 million units in 2025, the transformation from 0-1 to 1-10, multi-platform and multi-vehicle group operation, the company has carried out organizational upgrading, matrix organization and management and other changes. Li Bin said, "correspondingly, the ideal manufacturing system has also developed from a single factory production management to a multi-base, multi-factory and multi-vehicle manufacturing operation stage."

"in view of necessity and higher production efficiency and quality assurance, manufacturing upgraded horizontal coordination department, newly established MTM (vehicle management department), manufacturing operations department (multi-base coordination and operation quality KPI management), and upgraded manufacturing logistics (large logistics mode operation) and manufacturing EHS center (implementing multi-base EHS coordination)," he said.

After upgrading, the large-scale manufacturing operation management mode, through collaborative cooperation and sharing, more effectively supports the rapid development of the company's production demand.

"our role is twofold. In the manufacturing base, we are the R & D representatives who know best about product research and development, and in R & D, we are the manufacturing representatives who know best about manufacturing." Hai Liang, the person in charge of MTM, introduced.

Manufacturing vehicle Management team (Model Team of Manufacture), referred to as MTM, is the only team in the manufacturing system that uses English acronyms. At the beginning of the department, the partners did not know what MTM meant, so Hailiang's flying book signature has been hung with a "manual". Their self-positioning is bridge, standard-bearer, collaborative empowerment-internal implementation, external connection, to achieve the SOP of new products in the manufacturing base and rapid production capacity climbing delivery. Manage and plan the whole life cycle of each model business. From unfamiliar to familiar, MTM is now a word frequently mentioned by internal and external partners.

"in terms of production planning, manufacturing strategy and cost targets, we only recognize the input of manufacturing representatives." A certain model PDT manager said to the team. "Manufacturing representative" is one of the most important and popular roles in the IPD reform being carried out by the whole company. Every PDT manufacturing representative has the vision and responsibility of "number one" in the manufacturing business of the corresponding product line. This means that this group of manufacturing representatives are both omnipotent hexagonal warriors and "commanders" who co-ordinate manufacturing domain operations. They effectively realize the integrated management of the global manufacturing business and the whole life cycle management of the vehicle model in the manufacturing domain.

In this year's ideal L7 listing, in June and July, when climbing production hit 30,000 units, the MTM team played a huge role in capacity climbing, capacity flexible allocation and scientific production scheduling. " In view of the difficulties and sticking points of production capacity, we identify vehicle climbing and capacity allocation problems from a more professional point of view, and quickly reach a consensus with our brother departments to avoid delays in fighter jets. to meet the production capacity needs of different models of the company in the best mode of production, support the monthly sales target of 30,000.

"in the traditional automobile manufacturing industry, several major businesses such as production system, operation management and industrial engineering were originally embedded in the factory. This year, with the upgrading of the large manufacturing system, we unified the management of similar functions and responsibilities in multiple bases and set up a manufacturing operations department." After nearly a year of practice, Enlong, head of manufacturing system operations, has achieved initial results in the manufacturing operations department.

Multi-base unified standards. The unified deployment of manufacturing and operation, based on the standards of the mature Changzhou base, retains the current best practices and draws on the good practices of the mainframe factory. Gradually iterated to form an ideal automobile manufacturing standard, including quality system, team infrastructure, maintenance system and so on. "the new base in the future can be implemented directly, and the construction system will not be repeated inefficiently."

Multi-base alignment indicators. Enlong for example, "for example, to achieve the same 45JPH (45 cars per hour), what is the standard number of people? what is the management range of each monitor? what is the ratio of direct production to auxiliary production? good cases, tools in one place of experience feedback, other bases can be directly used."

The material management of central chemical industry is realized. Central management can "overlook" multi-base spare parts demand, coordinate sharing, and reduce the occupation of inventory funds. "assuming that different production lines in Changzhou base need the same spare parts, after analysis, we may need only one. Through allocation and sharing, it not only ensures the spare parts demand, but also reduces the inventory funds."

‎ multi-base collaborative collection and cost reduction. "as the scale of manufacturing and delivery has become larger and more parallel this year, we have shifted from purchasing for a single base to purchasing for a multi-base. Centralized procurement not only improves procurement and production efficiency, but also greatly reduces procurement costs."

As the operation of manufacturing operations matures, greater value is becoming more and more obvious. "when multi-base standards are pulled together and more and more best practices are precipitated, everyone can work in the same language, standards, and practices. Collaborative empowerment is becoming more and more convenient; quality problems and equipment failures that occur in one place can also be timely early warning and multi-base horizontal inspection, so as to avoid the recurrence of potential similar problems."

From single base to multi-base, from single model to multi-model, there is also the manufacturing logistics team that will do a good job of standardization and platform.

"from a single base to a multi-base, standardization is very important. how much area and crossing is needed for each base, how to set up the moving line of logistics, how many people are needed in the field, and how much equipment needs to be calculated and regulated in great detail." Ni Wei continued, "when we come to the stage of multiple models, we must quickly look at the number of platform parts, and expand the relevant proportion." One of the most remarkable evolution of manufacturing logistics this year is the linkage between logistics and product R & D and design. "Manufacturing logistics should put forward requirements for R & D and design from the perspective of high level, in order to help better product design and bring more help to improve manufacturing operations in the future, such as saving area, saving people, and increasing efficiency, thus driving down the overall operating costs of the company."

On the first day of operation from the Changzhou base, ideal Automobile began to practice the EHS (Environment, Health, Safety) management system, that is, environment, health and safety. With the rapid development of ideal cars from 1 to 10, EHS has also changed from single-base management to multi-base management, and the scope and extent of management are facing challenges and improvements. "EHS still adheres to its goal of 0 serious injury, 0 fire, 0 pollution, empowering and managing multiple bases according to the 'double 100% principle' to ensure the construction and operation of the factory and to be responsible to the government, society and the environment." Brother Qing, the person in charge of the ideal automobile manufacturing EHS, introduced.

From 2022 to 2023, we won many honors, such as Jiangsu Green leading Enterprise, Jiangsu Green Factory, Jiangsu second-level Safety Standard Enterprise, Changzhou excellent Fire Control Management Unit, Changzhou Environmental Protection demonstration Enterprise, Wujin Advanced production Safety Unit, and so on. From January to September 2023, EHS in Changzhou Base was inspected more than 100 times without a single case of punishment.

III. Professional committee to provide fresh blood to the talent team of the base.

"with the continuous increase in production and the continuous construction of multiple bases, our demand for talents is also greatly increasing, but now it is difficult to find technical talents suitable for us in large quantities in the market. in order to deal with the risk of talent shortage, we make plans in advance and consider filling the gap through self-cultivation earlier and more to prepare for larger-scale development in the future." Brother Hua, head of production in Changzhou base, shared it.

What makes us feel confident is that the company's talent training system is constantly improving. at the same time, the manufacturing interior has also spawned a horizontal cross-base virtual organization "professional committee"-the four major professional committees of punching, welding and coating. We can share the professional courses, experience feedback and cases in the production process of each base both online and offline, so that the growth of talents has the soil.

The professional committee is composed of four major processes of multi-base punching, welding and coating, aiming at the indicators of internal alignment quality, process and equipment, and externally perceiving the best practices and advanced technologies in the industry, so as to achieve efficient coordination and improve the overall manufacturing efficiency and product quality. produced the effect of 1: 1 > 2. " Take painting consumables as an example, if a base consumes 2 kilograms of bicycles and another base consumes 1.8 kilograms, then the professional committee will compare the differences between the two sides and find places where they can learn from each other. "

Jim, head of painting at Changzhou Base, shared that in the mass production of the ideal L7 special color dawning red, they encountered difficulties in the spraying process of colored varnishes. At the beginning, the qualified rate was relatively low, and it was difficult for the paint to be repaired again. " After being stuck by the process problem, everyone immediately discussed in the painting professional committee to clarify the manufacturing key nodes and defect points, and invited professional engineers and repair technicians to participate and support on-site. If we work together to do things well, we do not need to fight alone, nor can we close our doors. We will be more efficient in growing and solving problems, and we will get more with one stone. "

In 2023, the Professional Committee set up the "self-Research Project Club", and each workshop selected two outstanding engineers to join. The project aims at the self-programming, debugging, maintenance and other skills of glue-coating and spraying robots. " We know that more than 80% of the domestic factories are using outsourced methods for the introduction and debugging of new models, and we have mastered the technology of independent programming for new models, filling in the skills gap that has been stuck in the past. In the future, every new model of the company, we will save at least one million yuan in cost. " Jim introduction.

Brother Hua further interpreted, "this is a free university with rich resources. If he is a blue-collar worker, he can become a craftsman. If he is a white-collar worker, he can become an expert." The inheritance and transmission in the professional committee is not only knowledge and experience, but also the corporate culture of the ideal manufacturing team with the end as the beginning, the mission must be achieved, and the user value first.

In addition, the base has a wide range of professional application scenarios, and talents with growth needs can also carry out practical exercises in addition to absorbing theoretical knowledge. "the professional committee regards self-cultivation of talents as a common major topic, giving full play to their experience, knowledge reserve and joint promotion." Brother Hua said.

Conclusion:

Li Bin joined the ideal car five years ago. At the end of the interview, Li wanted to ask him: what are you most worried about joining the ideal? He said I was worried about sales. As long as you can sell it, I can build it.

"from the first thousand ideal ONE in the first month to over 30,000 in the current ideal L-series, during this period, we have achieved the quality and quantity delivery of the ideal ONE and the vertical climbing production of each L-series car. Facing the future, in the first month of the brand-new production line SOP, which is about to be put into production, double shifts will be opened, and the design beat will be produced at full capacity the next month, and the climbing speed will create another industry miracle." Li Bin kept his promise and led the iron army of ideal manufacturing to land efficiently all the time, giving full play to the power of extreme lean production and intelligent manufacturing to create extreme efficiency and high quality.

With the upgrade and evolution of ideal large-scale manufacturing in 2023, everything finally landed on the daily production delivery of the manufacturing system, pursuing the ultimate production, quality and cost efficiency.

"release is listed, listing is quantity, quantity is high quality", ideal speed has become the benchmark and leader of the industry. In the future, the excellent innovation management of both competition and cooperation of multi-base and multi-factory will continue to create great achievements.

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