China Quality News: "Change" and "Unchanged" Quality Concerto - Interview with Sany Group Co., Ltd

The picture shows Tang Xiuguo (first from left), President of Sany Group, introducing Sany's Manufacturing Execution System (MES) to guests

 

On January 30, Sany Heavy Industry, a subsidiary of Sany Group, acquired the German Putzmeister company, and the former competitor became a close partner. The founder of Putzmeister even half-jokingly said: "After visiting your factory, I knew that in the competition with you, the 'elephant' has long been out of chance." ”

Just more than 10 years ago, the construction site of the new terminal of the capital airport held a "big competition", and the concrete pump newly developed by Sany had to lose in the first confrontation with the "elephant" pump of the German Putzmeister company, and Sany people could only watch the "elephant" win the gold cup.

Trinity people tell this story with confidence that for them, such a change is just a matter of course. As they say, from an obscure small enterprise in Maotang Township, Lianyuan City, Hunan Province to China*5656, the world's sixth largest manufacturer of mechanical engineering products, in the more than 20 years of development of Sany, changes have been with us.

"Actually, we haven't changed." Tang Xiuguo, president of Sany Group, smiled: "Sany people only do one thing in their life, and that is 'quality changes the world'. ”
Be a person first, then do things. "Good people do good deeds, good people will have good motives, good goals, in order to continuously improve management, do a good job of products." Tang Xiuguo said that what Sany people want to change is not only an enterprise, but also the world image of "Made in China". Under the guidance of this baton, more than 70,000 Trinity people played a beautiful concerto of quality......

 

■ Science and technology forging quality

 

In the late 90s of the last century, in China's pump truck market, domestic enterprises could only produce short boom pump trucks below 32 meters, and the long boom pump truck market was all occupied by foreign brands. At that time, the length of the boom was made to 566136 meters, and the industry believed that it was more difficult to increase the boom by one meter than to ascend to the sky.

In the face of this situation, Sany, which is in the midst of vigorous development, is determined to develop a world-class concrete boom pump truck. From 1998 to April 1999, Sany's R&D team successfully developed 5656 units of 37 meters with independent intellectual property rights in ChinaConcrete pump truckIt was put into mass production in 2000.

Importing a 36-meter boom costs 1.1 million to 1.3 million yuan. The cost of the same product after independent research and development is 200,000 to 300,000 yuan. A boom has a profit of more than 1 million yuan, and this profit is a high return on technological innovation. In 2011, Sany made the long boom of the pump truck 86 meters, and this self-developed achievement once again refreshed the world record of 72 meters in the world * long boom pump truck created by themselves.

When others asked how long Sany's boom could be, Yi Xiaogang, CEO of Sany Heavy Industry, even said: "I don't know how long Sany* can make the boom last." But there is one thing I dare to say, from now on this world Guinness Book of Records will always belong to us Trinity. ”

Yi Xiaogang's self-confidence comes from Sany's great attention to scientific and technological research and development. Liang Wengen, chairman of Sany Group, often said that the return on fixed assets of an enterprise is very low, while the return on investment in research and development is very high. Over the years, Sany has spent 5% to 7% of its sales revenue on R&D every year, which is more than 3 times the average level of the same industry, and has invested nearly 2 billion yuan in R&D a year. Sany has established 9 test and testing centers and 58 laboratories to improve product quality from product research and development, process design, and process improvement. In Sany, the R&D department enjoys many privileges such as unlimited number of personnel and unlimited budget funds, while R&D personnel have the most smooth promotion channels, the most generous treatment and the most platform with room for growth. Once, everyone discussed what Sany's core competitiveness was, some people said it was marketing, some people said it was service, and an employee stood up and said that none of these were the same. He said that Sany's core competitiveness is that Chairman Liang is more "generous".

In Trinity, there are two sentences that researchers can't say in relative terms. *5656 is "This is how foreign countries design, and we design this way"; The other is "We haven't done it abroad, and we can't do it."

There is such a fact: in the construction machinery industry, there is a high-strength steel plate material, whose tensile strength reaches 1400MPa to 1500MPa. In the past, this material was imported from Europe. The tensile strength of this material in China is the most, and it can only achieve the strength level of 800MPa to 900MPa for mass production.

Can Chinese companies only be stuck by foreigners forever?

After several months of research and experiments, this special steel material, which is considered to be a "foreigner's patent" in China, was made by Sor people and put into mass production. Someone has calculated that in the past, the price of steel plates imported from abroad was 28,000 yuan per ton, and now the cost of producing 1 ton by themselves is less than 8,000 yuan. 1 ton saves 20,000 yuan, 60,000 tons a year, and this high-strength steel plate material independently developed by Sany will bring 1.2 billion yuan of benefits to Sany in a year.

The history of Sany is a history of continuous innovation. Sany's innovation not only fills many international and domestic gaps, but also conveys a kind of power, a kind of national brand to work hard, which makes the world look at Chinese enterprises and Chinese products with admiration, and also allows more domestic enterprises to stand up with confidence.

What has changed is the continuous extension of the length of the pump truck boom, the increasing weight of the crane tonnage, the innovative management model, and the courage and courage to break the technological monopoly of foreign enterprises and strive to be world-class.

 

■Quality reinforces quality

 

At Sany, quality is an unnegotiable thing, and it is the starting point of value and dignity. As a "dignity project", Sany Quality Engineering endows human dignity, enterprise dignity, and even national dignity in its products.

In the past, the handle of the transfer machine has been processed by the red bending process, which is not only time-consuming, but also has the potential danger of scalding. Not only that, when the round bar is heated, the performance will also be changed, the strength and wear resistance will be reduced, and the appearance quality will also be adversely affected. Any small detail can have a huge impact on the quality of the product. Zhou Fuwei, a scraper tooling engineer, was determined to change this seemingly inconspicuous process. "It's better to make a special forming mold, which only costs a few thousand yuan, and produces big results at a small cost." After two weeks of painstaking research, Zhou Fuwei finally made a special forming mold for handles. Using this special mold, only one person is required to work independently for the handle of the transfer machine, which greatly shortens the operation time, and at the same time completely eliminates potential safety hazards and improves product quality, which can be described as "killing three birds with one stone". This achievement is the first creation of the group and has high promotion value.

More than half a year has passed, recalling that thrilling time, Li Weixue of the Quality Assurance Department of Sany Heavy Industry still remembers it vividly.

The turntable of the roadheader is provided by the supplier, due to the unreasonable casting and process level of the supplier, resulting in problems such as rough surface, poor molding, and casting defects, the purchase pass rate of the turntable is 0%, and the refinement compliance rate is 0%. "What a shameful two 'zero eggs'!" Li Weixue took the project team to soak in the workshop all day long to study, wood and sand mold restructuring, sand mold selection, and casting process improvement...... If you don't want to be laughed at, you can only start from little by little. Half a year has passed, and the purchase pass rate of the turntable has reached 97.5%, the re-inspection rate is 0%, and the refinement compliance rate is 100%. "Quality engineering is dignity engineering, I have experienced it."

The pursuit of quality never ends. In 2010, more than 860 QC team projects were completed by all units of the Group, and the participation rate of employees reached 48.9%. Taking the crane division as an example, there are more than 140 teams in the whole division, and each team will produce two improvements every month on average.

Quality comes from details, and details create beauty. The improvement of every detail, the beauty of every weld and every cutting edge is a true portrayal of Sany people's pursuit of quality excellence.

Liu Wei of the No. 18 plant is reporting to work on the MES machine. "Through the MES function, it can realize a variety of functions such as production plan inquiry, job reporting, quality problem feedback, etc., and can automatically feedback the quality information and missing parts information in the production process to the corresponding production managers to realize the informatization of production management." With this system, the working conditions of the entire production line can be seen at a glance, and the LED display of the system will also be clearly displayed on the LED display of which link has the slightest quality problem.

Plant 18, the all-digital plant of Asia*5655, not only adopts a modern MES system for production control, but also is equipped with a large number of special tightening machines, press-fitting machines, power-assisted manipulators, pneumatic and hydraulic pulse tools and other advanced equipment on the assembly line, which provides a strong guarantee for the improvement of assembly quality and assembly efficiency, and makes the quality control stricter and more detailed.

"Uncompromising quality engineering must be achieved by scientific methods." Lean manufacturing and refinement are the soul and development direction of Sany's production, and lean thinking always runs through the entire manufacturing process. As the main advocate and practitioner of Sany lean management, Tang Xiuguo sighed that lean thinking has made Sany have been reborn. "The core of lean management is to eliminate waste, improve quality, focus on every detail, and create better benefits."

What has changed is the continuous improvement of the refinement compliance rate, the continuous reduction of the product re-inspection rate, and the constant is the excellence of every detail and the never-ending pursuit of product quality.

   

■ Service extension quality

 

The man had been standing by the construction site all morning, and from time to time he took out his mobile phone to take pictures of the concrete pump truck that was working. One day in 2011, a busy construction site in Langfang, Hebei Province, welcomed an uninvited guest.

"Is this pump truck easy to operate? Have you ever had a problem? "When the operator rested, this person took the initiative to come forward and chat." Good operation. In the past two days, the oil cylinder has a little bit of oil leakage, but it does not affect the use, and the manufacturer said that it will solve it for us in the next few days......"

The operator didn't expect that the few words he said inadvertently were quickly reflected to Liang Wengen, chairman of Sany Group.

At the headquarters of Changsha Sany Group, the regular quality service meeting of the pumping division is underway. Chairman Liang Wengen listened to the report while burying his head in making notes. No matter how busy he is, no matter where he is, Liang Wengen will rush back and attend this meeting on time, and he has never stopped for more than ten years. The incident in Langfang, Hebei Province in the report made Liang Wengen's expression extremely serious, and he demanded that the responsible person be dealt with immediately.

On the same day, the service manager responsible for the after-sales service of the Langfang area personally came to the door to apologize to the customer, and solved the problem of oil leakage from the oil cylinder in time; The relevant service engineers were asked to immediately return to the Changsha headquarters to review the business unit leaders in person, and conduct a one-month retraining at the headquarters.

After receiving the call, the service staff will arrive within 2 hours; Solve general faults for customers within 1 day; Commonly used accessories will arrive accurately within 1 day. This is Sany's "211" service commitment. If the customer's construction is affected due to time delay, Sany will pay compensation on an hourly basis. In Sany service, there is no excuse such as "come back in a few days to solve the problem".

The uninvited guests who appeared on the construction site were called "mystery customers" by Trinity. Who they are, where they will appear, no other department, anyone except the chairman's office, knows nothing about their situation. They are like Sany's invisible "eyes" and "ears", and where there are Sany products at the construction site is the place they "visit" every day.

One year, on the first day of the Lunar New Year, a customer called and said that the *5656 thing he was going to do in the New Year was to make this call to thank an engineer from Sany. It turned out that this customer was rushing a project before the Spring Festival, and the engineer had been staying with him, ready to overhaul the machine for him at any time, and he stayed with him at the construction site for 36 hours. After the completion of the project, due to a sudden power outage, some concrete remained in the pump truck, and the service engineer forced his hands to pull it out and dry it for more than 4 hours to save the customer's machinery from damage. The customer said with emotion that a company with such a show employee must be a show company, and he will buy Sany products no matter what in the future.

The ECC system developed by Sany is the most advanced service information platform in China, which makes Sany's products become "smart machines that will go online", and makes remote diagnosis and remote solution of construction machinery products a reality.

Sany also has a well-known "nanny team". Every time a new product enters the customer's construction site, there will be a Sany special engineering machine for a period of six months to two years of 24-hour special car special service, and at the same time for the customer to train user-level equipment operators, just like a nanny to care for the baby.

Always provide products and services that exceed customer expectations, and beyond that, Sany subverts the service concept of the entire mechanical engineering industry. A customer who bought a Sany crane said excitedly: "Thank you Sany for entering the crane industry!" Your entry has led to the progress of the service quality of the entire industry! In the selection of "National Customer Service Public Satisfaction * 5654 Model Enterprise" organized by the Ministry of Commerce, Sany is the first enterprise in the domestic construction machinery industry to win this honor.

211 service commitment, mystery customers, ECC system, "nanny team", the improvement of service quality is also a kind of "reversal" of product quality improvement. Quality is always Sany's unremitting pursuit to meet customer needs, and it is a better language for Sany to dialogue with customers and the market.

What has changed is more and more demanding service requirements, is more and more advanced service means, and what remains unchanged is the importance of customers and respect for quality.

Times have changed, places have changed, factories have become bigger, and there are more workers...... Everything is changing, but the core value of "quality changes the world" has been with Sany for more than 20 years, and has been remembered and practiced for more than 20 years. From every conversation with Sany people, from every product launched by Sany people, we have reason to believe that Sany people will continue to play this beautiful concerto on the big stage of world machinery manufacturing......

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