Humanity ushered in the era of Industry 4.0, and Internet of Things and manufacturing services ushered in the "Industry 4.0" that is led by intelligent manufacturing. Its aim is to make full use of the combination of information and communication technologies and cyberspace virtual systems - information physics systems. The means to transform manufacturing into an intelligent one.
From 1913 when Henry Ford invented the automobile flow production line to today's auto full-automatic production line for more than 100 years, the automotive production line gradually upgraded from “manufactured†to “intellectual-made†and also witnessed the history of human industry from industrial 1.0 to industrial 4.0. The transformation. For more than one hundred years, how has the "core" of the automotive industry, the auto production line, evolved and evolved? Today we come to find out!
First, the bud: Ford Motor's auto production line production
In 1913, Ford Motor Co., Ltd. first established an assembly line assembly system. As a result, it triggered an earth-shattering revolution in the world's auto manufacturing industry and promoted the scale of auto production. Ford's assembly line has one station for each task, which means that hundreds of cars can be produced at the same time throughout the factory.
In Ford's original factory, the Ford T model was assembled 93 minutes from start to finish. Actually every three minutes, a complete trolley is rolled off the assembly line. This is the beginning and sprouting stage of the automobile production line. At the same time, this stage makes the car no longer exclusive to the rich, and thousands of ordinary people can afford to own their own cars.
Second, Innovation: Japan's "Just-in-time Production" JIT Production Method
In 1953, Japan's Toyota Vice President Ohno Naiichi integrated the characteristics and advantages of one-piece-flow and mass production, creating a high-quality, low-consumption product in a variety of small batch production conditions. The production method is just-in-time production (JustInTime, JIT for short).
JustinTime (JIT), also known as stockless production, means that the necessary parts are delivered to the production line at the necessary time and in the necessary quantities, and only the required parts are available. Only in the quantity required, it is delivered to production only when it is just needed. Therefore, the starting point of the just-in-time production system is to continuously eliminate waste, reduce inventory, and carry out continuous cyclical improvements.
The basic idea of ​​JIT's production methods is to "produce the required products only when they are needed, according to the quantity they need," that is, to pursue a production system that is not stocked or has the minimum inventory. The basic idea of ​​JIT is production planning and control and inventory management. Therefore, the JIT production model is also called "lean production."
Third, development: automated workshops and factories
After the 1950s, an automated, semi-automated production line began to appear, known as a rigid automatic line. In particular, the development of electronic computers and automation technology has greatly facilitated the automation of the production process.
In the 1960s, industrial production began to use electronic computers for optimal control of large-scale equipment, such as large distillation towers, large-scale rolling mills, etc., and achieved direct digital control (DDC) and setpoint control (SPC).
In the 1970s and 1990s, the development of automated instrumentation and hardware and the advent of microcomputers enabled the automation of production processes to enter a new high-level stage. The centralized control of the entire plant or the entire process flow, the use of computer systems for comprehensive multi-parameter control, or the use of multiple computers for hierarchical integrated control of the production process and participation in business management is the main feature of this stage.
Since the beginning of the 21st century, the concept of “people-oriented†and “energy saving and environmental protection†have gained deep roots in the hearts of people. Factory automation is progressing toward integrated factory automation (also known as overall automation). According to the survey conducted by the American Academy of Sciences, the automobile factory adopts integrated control of the whole plant, which improves product quality by 2 to 5 times, production efficiency by 40 to 70%, equipment utilization by 2-3 times, and production cycle by 30 to 60%. The engineer's ability to work increased by 3-5 times.
IV. Evolution: Intelligent Manufacturing in the Age 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†that is led by intelligent manufacturing. It aims to make full use of information and communication technologies and cyberspace virtual systems—information physics systems. Combined with the means, the manufacturing industry will be intelligently transformed.
The automotive industry as a representative of the higher degree of intelligence in the manufacturing industry, the German Mercedes-Benz car company, BMW Group, Volkswagen Group, Bosch companies have taken the lead in testing the water industry 4.0. In China, companies engaged in automobile manufacturing also began to think about the transformation of the 4.0 era. For example, the Dongfeng Nissan factory became a pioneer in the “Industry 4.0†era. In 2017, Dongfeng Nissan fully implemented the “i? Planâ€. Its “Intelligent Quality†is the intelligent upgrading of manufacturing technology, the transformation of factory automation, the construction of advanced engineering technology center, and the digital development platform, intelligent precision manufacturing and information technology. Quality management with "smart" quality. Such as:
1. Fully upgrade factory automation to ensure high quality product output
In 2016, Dongfeng Nissan Four-Five Factory fully introduced the new flexible and intensive automatic production line, which can realize the order production of the entire vehicle system, and reduce the occupied area by 30% to 50%, and reduce the total vehicle and parts inventory in the library by 20%. The automation rate will continue to increase over the next three years. For example, stamping technology, welding shop, painting shop, and resin shop are all applying advanced automation technology.
In terms of final assembly, new technology projects such as dashboard automation assembly, engine & transmission automation, and new robot applications have also been completed. The newly-introduced rims auto-foil, oil tank automatic sequencing, and other automation improvement projects will increase the automation rate. To 12.5% ​​(with an average automation rate of 7 to 8% in the industry), it is the leading level in the industry.
2. Using forward-looking intelligence technology to incorporate technology into the core of the product
In terms of forward-looking smart technology, Dongfeng Nissan started to use the domestic advanced "engineering system" Advanced Engineering Technology Center (AEP) in 2016. The newly-completed AEP will assume the three major functions of creating a new smart green factory, product development over the same period, system construction, and expert talent cultivation. It will provide digital development platforms, intelligent work tools, and big data quality management. Its highlights include VR virtual evaluation technology, 3D printing rapid prototyping, green friendly robots, laser on-line measurement, machine sensing and IOT, blue light scanning, and ultrasonic solder joint detection, and continues to improve the quality of intelligent manufacturing.
3. Full-range intelligent monitoring system, automatic alarm of the production line
In terms of quality control, the Dongfeng Nissan Engine Factory uses the concept of smart manufacturing. The entire system assigns ID cards to each product, automatically collects the data of each project, and connects the related information through the unique identity given to it. Trajectory data, accurate data collection, unlimited possibilities for data applications, product, equipment, production lines, models and other dimensions can be accurately tracked, and automatic warning of the production line to prevent the flow of defective products.
to sum up:
From the automotive assembly line in 1913 to the smart manufacturing of today's automobile factories, under the rapid development of science and technology over the past 100 years, industrial production has become more and more intelligent, and it has succeeded in stimulating an industrial revolution and industrial upgrading in the world. . Nowadays, foreign automakers have gradually stepped into Industry 4.0. Domestic automakers such as Dongfeng Nissan are advancing with the times, integrating the wisdom of “i?plan†into the production system, enhancing their core competitiveness, and serving as a vanguard of the auto industry. Leaders, outline and practice the blueprint for the future development of the domestic automobile industry. How will the automotive industry evolve in the future? We will wait and see!
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