In summer in Shanghai, the sweltering weather can easily make the temperature in the workshop exceed 40 degrees Celsius. What is even more "fueling the fire" is that the temperature of an oven used for a hot jacket operation on the assembly line can reach 180 degrees Celsius! Almost every assembly worker ’s work clothes were soaked with sweat over and over, and sweat dripped on his face like rain.
Recalling the Shanghai Mitsubishi Elevator Factory 20 years ago, the most memorable thing about the technical "old mage" Chen Yong was the "oven" -like workshop life in the hot summer season. The scene of sweating and busy working as if yesterday.
赶上了“中外合资企业潮” 01 Catch up with the "tide of Sino-foreign joint ventures"
In the 1980s, with the deepening of reform and opening up, Sino-foreign joint ventures continued to emerge. Shanghai Great Wall Elevator Factory chose to take the road of joint venture development, contacted many well-known elevator companies in the world, and on the basis of "three comparisons" and cautious, finally selected the elevator manufacturing company with advanced technology in the world. Denki Corporation as a partner.
In February 1986, the State Planning Commission, the Ministry of Urban and Rural Construction and Environmental Protection and other four ministries issued a document approving Shanghai Mitsubishi Elevator Co., Ltd. as a Sino-foreign joint venture with a duration of 20 years.
In January 1987, Shanghai Mitsubishi Elevator Co., Ltd. was formally established, and the investors were:
Shanghai Mechanical & Electrical Industry Company (65%)
Japan's Mitsubishi Electric Corporation (15%)
China National Machinery Import & Export Corporation (10%)
Hong Kong Ryoden Engineering Co., Ltd. (10%)
In 1995, investors changed to:
Shanghai Mechanical & Electrical Co., Ltd. (52%)
Mitsubishi Electric Corporation (32%)
China National Machinery Import & Export Corporation (8%)
Japan Mitsubishi Electric Building Technology Services Co., Ltd. (8%)
Huge and advanced equipment, dense Japanese manuals, the first call to a Japanese expert, carefully followed the Japanese experts to learn the equipment ... In the newly established Shanghai Mitsubishi Elevator Co., Ltd., everything is brand new, Chen Yong first He intuitively felt his gap.
What to learn? How to learn Who to learn from?
A series of questions were thrown to the workers. Recalling the year of learning technology, Chen Yong said that there was an opportunity to study at Mitsubishi in Japan, and everyone took a look while taking pictures. . "
Comparing these detailed photos, the workers immersed themselves in research, colleagues explored each other, dismantled the research, and installed it by themselves. Step by step tedious procedures, unable to operate one by one to find the problem one by one, relying on diligence to make up for it, Shanghai Mitsubishi Elevator is operating normally.
从劳动密集型向技术密集型转变 02 Transition from labor-intensive to technology-intensive
For a long time, as the core mechanical component of the elevator, the traction machine has been the bottleneck of elevator manufacturing. Due to the special mechanical structure and the acceleration of product upgrading, the production mode has been a labor-intensive manual assembly mode. At that time, increasing productivity required workers to work "three shifts."
Manual assembly site of original traction machine
In 2015, when the new LEHY-III-S traction machine was put into production, Shanghai Mitsubishi Elevator put forward a new traction machine assembly concept, incorporating the most advanced technology of intelligent manufacturing into the assembly line of the new traction machine, completing the world-leading Horizontal elevator traction machine assembly line.
But the previous technology is not enough, which is a new challenge for them.
The development and commissioning process of the assembly line is difficult. Technology, development, production and other departments form a technical team, working together to participate in the consideration of various factors such as product components, operating processes, product replacement, and repeated calculations and simulations. The original plan was overturned and recaptured dozens of times. One technical problem after another ...
Equipment technician Chen Hao told this story to reporters: In order to cover the production of a series of traction machines at the same time, traditional production lines often require a lot of time to change production when switching between different models of production. At that time, the production efficiency was low, and the production could not be organized according to the order.
After repeated trials, the technical team uses MES software running on the server to manage, and automatically organizes production according to the order through network communication to achieve automatic matching of parts and components, automatic adjustment of tooling fixtures, and seamless connection of model switching. Technologists practice while groping. From scratch, they have independently developed software systems with complex procedures.
智造是为了更好的用户体验 03 Smart manufacturing is for better user experience
In May 2016, one "big guy", an industrial robot, appeared at the workshop site.
The unmanned KUKA robot arm is operating automatically, and the factory's automated production line is methodical. Workers observe the data in the equipment room and control the automated production in real time ...
There may be many answers. Since equipment suppliers are also involved in similar high-demand intelligent assembly lines for the first time, they also lack experience. Equipment operation interfaces designed by different engineers have no uniform format standard, which is cumbersome, complicated, and different operation forms, which leads to operations. Habitual errors.
The experienced team leader made a lot of homework to learn the equipment program. After finding the source of the problem, he communicated with the software engineer and put forward a lot of constructive suggestions for improvement. He also hand-drawn the operation interface for reference to the equipment supplier, and made reference to the new software version. Trial operation interface, and through continuous optimization and improvement, the system operation interface will be unified, concise, and easy to operate at a glance.
However, equipment failures were unexpected.
Near the end of August, BUG appeared in the equipment debugging software. The robot fixture collided with the buffer tray, which caused severe deformation of the fixture and made it unusable.
Suddenly, the equipment supplier took a long time to re-fabricate the fixture and did not have the ability to repair it on site, so it was not possible to replace the damaged part in the first place. Although the assembly line is still in the trial production stage, the production capacity of the entire line is much higher than that of manual assembly, so it has been produced while debugging.
In order not to affect production, the team leader relied on his accumulated work experience to analyze all the components of the fixture by analyzing the structure of the fixture and use a press to shape the frame.
Since the reshaped frame cannot be restored to its original state, scrapering is performed on all rail mounting surfaces with errors to ensure the accuracy, so as to ensure the smoothness of the linear guide after adjustment.
Finally, the servo motor was installed. Due to the cramped environment on the site, they had to lie down and kneel again during maintenance. In this case, it was repaired for 12 hours and the fixture was not repaired until 2 a.m. the next day, and the performance of the gripper was found to be better than that of the original equipment manufacturer.
Afterwards, even the equipment suppliers praised it. In order to ensure the commissioning and production of the assembly line the next day, the team leader who did not take a few hours of rest appeared at the production site at 7:00, and made management improvements to prevent the recurrence of such failures.
"Many times solving problems requires subverting traditional craftsmanship, and exploring while innovating," said Weng Zhijie, a workshop operator. "Now the intelligent assembly line is very new, high-tech, and low labor intensity. These characteristics have also raised higher requirements for our workers. Claim."
With the successful assembly of the LEHY-III-S traction machine assembly line, workshop assemblers no longer need to work around an oven at 180 degrees Celsius, and the transportation of the traction machine can get rid of the slow and tedious crane lifting, and the drilling of the machine tool It is delivered directly to the special plane, with higher accuracy and faster efficiency.
The data shows that before the assembly line was adopted, each worker produced one traction machine a day; after using the assembly line, each person could assemble eight traction machines, increasing the efficiency by 8 times. LEHY-III-S traction machine intelligent assembly line is one of the most advanced traction machine assembly lines in the world.
Nowadays, in the famous "Three-piece Kitchen Set" in Shanghai Lujiazui—Jinmao Building, Shanghai World Financial Center, and Shanghai Tower, there are "two pieces" of elevators that rely on Shanghai Mitsubishi Elevator to install and maintain. Citizens and tourists fully appreciate the "up and down enjoyment"
In 1998, Shanghai Mitsubishi Elevator installed the Mitsubishi Elevator with a speed of 9m / s for Jinmao Building, which became the fastest elevator speed in use in Mainland China at that time.
In 2014, Shanghai Mitsubishi Elevator installed the Mitsubishi Elevator with a speed of 20.5m / s and a travel distance of 578m for the Shanghai Tower, the tallest building in China. From the second floor to the 118-story sightseeing hall, it only takes 53 seconds, setting the world's fastest, Elevator with the longest journey has two records.
In addition, the Shanghai Center also installed a Mitsubishi double-decker car elevator with a travel of 470m and a speed of 10m / s, setting a record for the longest double-car elevator in the world. The elevator's in-car air pressure regulator is the first in Mainland China. Times application.
"Are you proud of the wisdom of the company?"
"In fact, we are still very junior." The words of Chen Yong, an "old mage", are extraordinarily modest. "Smart manufacturing is for a better experience. It may be work experience or user experience. We have more room to go. Work. "