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The initial cleaning technical reform project for the P10 production line cylinder head has been successfully delivered.
Time:
2022/04/25
The cylinder head is one of the core components of the engine, and its surface and internal cleanliness will directly affect the quality of the engine. Cleaning is an important process to ensure the cleanliness of the cylinder head. To meet the strict quality standards set by Weichai, the cleaning solution in the cleaning machine needs to be changed once a week to meet the cleanliness standards of the cylinder head. The consumption of the cleaning solution is very large, and it also requires significant costs and expenses. How to ensure production quality while effectively reducing costs is a challenge facing the company.
To this end, Han Yuechao from the manufacturing department, Zhao Xuehao, and Zhang Zhenxiao from the technical department have made this challenge their focus.How to ensure product cleanliness through technological transformation while reducing the cost of the cleaning solution.Efforts do not disappoint those who are dedicated. After repeated experimental efforts, they made technological improvements to the cleaning process without increasing the number of procedures.Using the existing cleaning machine's electrical cabinet PLC control, they installed a preliminary washing mechanism. When the product passes through the preliminary washing mechanism, it is initially sprayed and rinsed with old cleaning solution before entering the cleaning machine. This not only cleans away the debris left from the processing but also pre-rinses the residual gun oil and rust remover from the gun drilling process, thus maintaining the lifespan of the subsequent cleaning agent.
This technological improvement, compared to the previous method where the cylinder head directly entered the Duer cleaning machine, not only further improved the cleaning quality but also effectively extended the lifespan of the cleaning agent—from changing the cleaning solution once a week to once every two weeks, significantly reducing manufacturing costs while also improving the cleanliness quality of the product.
Behind small innovations lies great wisdom! This preliminary washing device was independently designed and manufactured by the project team, making full use of idle old materials. After installation, debugging, and trial operation, the results were significant! A preliminary estimate shows that just in cleaning costs alone, it can save 800 yuan per week, leading to an annual comprehensive cost reduction of over 38,500 yuan.
The above image shows the preliminary washing device independently designed and manufactured by the project team.
Since the company launched its innovation and efficiency enhancement project management, various departments have overcome difficulties, and good news has been frequent. They have responded by establishing innovation and efficiency enhancement projects, and many small cost-reduction initiatives are blooming everywhere, yielding significant results, which is encouraging.
Weifang Sibao Precision Technology Co., Ltd.
Operations Management Department
November 24, 2021
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