Manufacturing Transformation - Sany Group builds core competitiveness

"Hunan Daily" on May 27 (Reporter Tang Aiping)In the first four months of this year, Sany Group achieved a total sales revenue of 7.3 billion yuan, a year-on-year increase of 46%. It is particularly gratifying that piling machinery, hoisting machinery,Port machineryand the sales of coal machinery and other products have doubled.
The good performance is attributed to a series of scientific research and technological transformation projects implemented by Sany in recent years. However, when the reporter interviewed Tang Xiuguo, president of Sany Group, he did not talk too much about the investment in the project and the progress of equipment, but more about the changes brought about by the lean manufacturing reform that the company is implementing. He believes that lean manufacturing runs through the whole process of R&D and technological transformation, and is becoming another core competitiveness of Sany.

The decisive victory is on the spot

New technology, new technology, new materials, new equipment, is the key word of all new projects, welding robots, CNC machining centers, automatic testing lines and other high-tech equipment, so that Sany manufacturing like a tiger wings. But at the same time, the improvement of the manufacturing process is also receiving more and more attention from Sany.
On May 22, the sound of the machine in the No. 12 factory of Changsha Sany Industrial Park was harmonious, welding sparks were splashing, and cars were walking back and forth. Zhu Xuchang, deputy director of the manufacturing business department and director of the manufacturing department of the crane division, told reporters that all the welding, machining, assembly, painting and other processes of the crane are completed here. With the improvement of the production process, the situation of the original serious shortage of production capacity has been greatly improved, and the entire production line has become easy and smooth. This is a microcosm of Sany's lean manufacturing transformation.
"The decisive battle is in the market, and the decisive victory is on the spot". The management of Sany Group believes that a good product not only means advanced R&D technology, but also a sophisticated manufacturing process. Sany must build the "golden key" of fine manufacturing, in order to shorten the gap with international enterprises and comprehensively enhance international competitiveness.
A manufacturing revolution centered on lean production has unfolded in Sany. Since the second half of last year, the first batch of 26 projects have been launched. "Let the problem be solved in the process of production." "The previous process is always responsible for the next process." Overcoming the common shortcomings of "large waste, chaotic process, and unreasonable resource allocation" in manufacturing enterprises is the ultimate goal of this change.
The change has further strengthened Sany's on-site management. Once, Ouyang Min, the minister of crane quality assurance, found that there was rust in the inner cavity of the crane legs. At the meeting of the business department, he proposed that "the inner cavity of the outrigger needs to increase the painting process", and after this suggestion was implemented, the inner cavity of the outrigger became smooth and bright, and the appearance was greatly improved.
HAECO is committed to the refinement of parts and components, and through the improvement of the process, the welding that affects the appearance of products is gradually eliminated. In addition, a special inspection system has been established for the burr, deformation, primer and other items of structural parts of the appearance quality of the whole machine. The product manufacturing is more standardized, standardized and accurate, and the appearance quality of the whole machine is greatly improved.
With the deepening of the reform, the completion rate of the enterprise plan has also risen sharply, the production capacity has been greatly increased, the product inventory has decreased, and various wastes have been gradually eliminated. As a test field for Sany's lean manufacturing reform, the average utilization rate of key equipment in the crane division increased by 26% year-on-year, and the assembly and warehousing cycle was shortened by 22%. This year, with a 5% reduction in production sites and no increase in personnel and equipment, the production capacity has doubled in five months, and the per capita output value has increased by 85.63% in one year.
From January to April this year, the quality index of Sany Heavy Industry was further optimized by 30% on the basis of last year.

"Improvement" is deeply rooted in the hearts of the people

With an annual output of 1,000 sets of lifting machinery, Ningxiang Industrial Park and other projects have started, according to the plan, hundreds of high-precision equipment will be introduced, and in greening, smoke and dust control, etc., fully up to the standard, to build an ecological, garden-style factory.
Lean manufacturing has become a system in Sany. Refinement promotion groups have been established in each subsidiary, and refinement special meetings are also held regularly in each company.
Lean manufacturing requires enterprises to have a driving force for continuous improvement and the pursuit of the best beauty. In Sany, improvement, as an important part of corporate culture, has also been deeply rooted in the hearts of the people, and improvement has become a conscious and voluntary action.
"Lean production is fundamental, if you don't change your thinking, you will change people!" The devil is in the details!" This is the determination and ambition shown by the ordinary front-line workers of the outrigger cold work and assembly work center of Sany Crane Division when applying for QC projects. A spontaneous "improvement action" by the workers of the center was even more popular in Sany.
Gu Yongtian, the person in charge of the center, told reporters that in the past, because the leg cold work team site is small, and the 4 welding platforms occupy a large amount of space, the circulation speed is slow, and in the process of operation, because there is only one crane, there is often a phenomenon of shutdown and waiting, in order to improve the working environment and improve product quality, the leg cold work team independently proposed the improvement method of active leg welding, and through the use of the leg welding line, 4 welding platforms were omitted. It is reported that at present, the participation of all employees in the crane division has increased significantly, and 58 QC projects have been declared, with a team QC penetration rate of 73.8% and a completion rate of 61%.
And that's just a good start. The Lean philosophy is starting to prevail not only in manufacturing, but also throughout the Group. Tang Xiuguo introduced that the growth rate of Sany this year is expected to be more than 50%, but the number of management personnel will not increase. This is the energy of improvement.

A declaration of confidence

Tang Xiuguo, President of Sany Group: "Quality changes the world" is the essence of Sany cultural concept. Continuously improving product quality and conquering the global market with high-quality products is the belief of Sany people. In the field of manufacturing, Sany does not dare to call it better, but will do its best to *5655. As long as we achieve breakthroughs in our respective fields and complement each other, the image of "Made in China" will get better and better, and it will win due respect in the international market.