Winning by quality: Engine Division insists on the path of quality upgrading

Engine division staff and certificate photo

The relevant staff of the Engine Division said that the case closely follows the spirit of “reducing quality and reducing costs, creating double-rate growth, and acting” to accurately identify the bottleneck process. In view of the problem of speeding single-edged gun drilling and poor penetration, the correlation diagram analysis is drawn to find the five end factors that affect the speed of the gun drill. The new QC team of the heavy machine department uses a large number of quality tools and statistical data to improve the accuracy of the equipment by improving the gage structure, making the eccentric guide bushing, and testing the new material single-edged/double-edged gun drill to improve the processing tempo, reducing the beat to In 22.4 seconds, Nissan upgraded 30 units and the cost was reduced by 156,000 yuan.

It is understood that the engine business department has continued to strive for excellence in quality improvement and cost reduction for decades. As early as 1993, it put forward the quality of “quality is life, life is only once”. The core concept, and put forward the decision to carry out "life engineering" in quality work, and position the quality work of the engine division in a position closely related to the survival and development of the enterprise. In order to ensure that every engine sold is a boutique, the engine division pays close attention to quality from procurement to manufacturing, so that quality management is always at every stage.

The first is to pay close attention to the quality of procurement parts and ensure that "no inflows are bad." In the supplier selection, a strict supplier selection, evaluation, monitoring and management process has been established. It must be a domestic first-class and internationally advanced supplier that has passed ISO/TS16949 quality certification. At the same time, we established a strategic partnership with suppliers to achieve the goal of “same direction, responsibility, strategic alliance, harmony and win-win” and established a sound supplier management system. The procurement process and requirements were clarified through more than 10 documents including Supplier Manual, Purchasing Control Procedures, Supplier Selection, Evaluation and Monitoring Control Procedures, and Production Part Approval Process. In addition, the Engine Division has implemented a quality defense line to move forward to suppliers, and the quality position has extended the strategy to OEMs and end users. Through the establishment of special parts production lines, formation of expert groups for supplier assistance, implementation of joint quality research and improvement, holding joint quality meetings and other initiatives, exchanges and communication, improve the quality of procurement parts. In 2017, it assisted suppliers 18 times in total, reducing the failure rate of component assembly and adjustment by 28%; visiting the OEM to proactively find 7 problems and reducing the market zero-kilometer failure rate by 9%.

The second is to pay close attention to the quality of self-made parts and ensure that "badness does not flow out." Through the establishment of the information digital management system, ERP effectively gathers, manages and controls all the information in the diesel engine production and operation activities, and builds a digital management system of “internal and external interconnection, up and down interconnection, and efficient operation”. In production, from information collection, sorting, measure determination, improvement implementation to closed-loop verification, daily review is carried out, effectively improving the speed of production improvement; in the market, through information collection, failure analysis, improvement implementation to verification loop, With the help of the network auditing system, the fault database system is processed, which effectively improves the speed of market quality improvement.

Worker is working

In addition, the Engine Division is actively carrying out quality activities of “all staff, full position, whole process, and whole system” to ensure zero defects in the process and control of the quality of the whole machine. In the past September, the quality month event with the theme of “liberation of quality and responsibility” was launched. All departments took the overall quality of ideas and goals of the year as the leader, focusing on the “four major projects” of the company, and improving the quality of the physical products. Improve the quality of the system and build a quality defense line for the successful completion of production goals and tasks in 2018. During the quality month, the heavy machine department released the A3 solution report of 13 questions including “Optimizing the production cycle of the CA6DM cylinder head line OP25 process” and “avoiding the oil pressure sensor harness being burnt”, which started at the door. The quality work boom of “Everyone values ​​quality and improves everyone's quality”. At the same time, the heavy machine department also adopted the form of cross-checking of special lines to optimize the process discipline inspection method. For the engine appearance quality problems such as paint lacquer and paint leakage, and 45 items, the documents were imperfect and the implementation was not in place. Ensure that the quality of CA6DM products is stable and controlled. According to the guiding ideology of the quality month activity, the sports department department organizes the director and the squad leader to conduct irregular inspections to prevent the defective products from flowing into the next process. In addition, the frequency of inspections by extra-line personnel has been increased, and all dimensions are strictly in accordance with the documentation requirements. During the period, the rate of defective products in the CA6DM connecting rod line group was reduced to less than 0.35%, and the average passing rate of one-time inspection was also increased to 99.9%, which exceeded the quality requirements of the engine division. The processing workshop takes "quality month" as an opportunity to take the quality accidents that have occurred in recent years as a case to deeply analyze and strengthen the quality awareness of employees. At the same time, special inspections were carried out for the use of measuring tools, and 22 irregular behaviors were rectified, which effectively improved the accuracy of physical quality testing. In addition, the self-inspection and re-inspection of each process are carried out simultaneously, and a mechanism of mutual supervision and mutual supervision is formed within the employees, which enhances the timeliness and authenticity of the inspection and effectively improves the control of the product process quality.

Advanced quality concept, strict quality standards, and scientific quality assurance methods... The engine division spares no effort in the road of quality upgrading. It has won the honor of the National Quality Award and realized the overhaul of the heavy machine Aowei 2 million kilometers without light repair. With a number of quality achievements such as 40,000 km long oil change, the company has explained the responsibility and responsibility of the “domestic leading international first-class” Chinese internal combustion engine enterprise with practical actions, which has promoted the improvement of domestic industry quality management and economic development, and the quality of Chinese diesel engines. Horizontal shoulders international.

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