Workers' Daily丨"March 1st" overnight, touching the pulse of manufacturing upgrading

At 10 o'clock in the evening of April 16th, the evening breeze was blowing, and the lively Changsha County in Hunan Province gradually quieted down, but the lights were still bright in the No. 18 plant of Sany Heavy Industry, and more than 10 pump trucks went to the world from here tonight.

This is Asia's * 5655 intelligent manufacturing workshop, covering an area of more than 100,000 square meters, with concrete machinery, road machinery,Port machineryand other production lines, all links are automated and informatized.

Here, you can touch the pulse of the transformation and upgrading of the manufacturing industry up close.

"My Robot Colleague"

The palm trees are like a cover, the pavilions are scattered, the water is gurgling under the feet, and the flowers are blooming beside you...... The reporter felt as if he had arrived in a park. This is the rest area of Plant 18. At the end of the day's work, Peng Baixiong, the overtime team leader of the valve block machine, was resting here.

Peng Baixiong's team of 60 people is mainly responsible for the machining sequence of key valve blocks, flanges and transfer cases of the hydraulic system of concrete equipment and road machinery equipment.

* There are more orders in the factory near the factory, and the work tasks of the team are also increased accordingly. Peng Baixiong was busy from 8 a.m. to 10 p.m., and after a busy day, his blue overalls were still clean and tidy. "Thanks to my robot colleagues." Peng Baixiong told reporters with a smile, "You only need to press a button to complete 10 processes with quality and quantity." ”

In Peng Baixiong's view, valve block machining is a simple and complex work, the production line has a large number of digital machine tools, workers only need to strictly follow the production scheduling of the MES center, set up the program, can realize the production of valve block off the line.

In recent years, due to the acceleration of equipment technology upgrades, as well as the increase in customer customization needs, the valve block machine processing team has also ushered in the challenge of highly "flexible" production, sometimes two or three days to change one, * more than a month can change 40 kinds of parts, which means that they may have to face new workpieces and new tasks every day. Peng Baixiong, who is nearly half a hundred years old, still actively participates in the automation equipment training courses organized by the company to "recharge" himself.

People and robots are living in harmony, and robots have become the most trustworthy partners of employees.

In the work center of structural parts, blue flames continue to burst out, and the "welding robot" is methodically welding more than 30 welds. This robot is the "old buddy" of welder Li Zhu, who has been working together since 2010, "It can work 24 hours a day." The welded seam is neat and flat, and there is less welding slag."

Yang Lijun, the welder squad leader, is responsible for the total assembly line, except for 2 links operated by 5 workers, the rest are completed by 11 robots. "Robots take over 90% of the work, which is so easy." Yang Lijun said.

"Secret Weapon"

At 1 o'clock in the morning, a piercing warning suddenly came from the pump truck production line, which woke up the sleepy reporter.

This is a reminder to the worker to proceed to the next process. Following the prestige, pump trucks of different models and colors on the production line are parked on the automatic crawler and waiting for further assembly.

The traditional pump truck production line can only produce one or two models, while each production line here can produce 5 to 10 models, and the whole plant can produce up to 69 models. "In the past, there were more than 800 workers in the two pump lines, but now there are only more than 200 workers, but the per capita efficiency has increased by 400%. The workshop can now bring one pump truck off the assembly line in one hour. In the Shanghai Lingang excavator production workshop, an excavator can be rolled off the assembly line in 5 minutes. Pu Mingjun, the leader of the assembly team, said, "Now not only the assembly efficiency has been improved, but the workers' work is also safer and more convenient." ”

The heavy lifting of transporting parts from the warehouse area to the production line is already carried out by AGVs (Automated Guided Vehicles). Workers place orders for the materials they need in advance, and the AGV unmanned trolley automatically distributes them to place. The white transparent plastic strips on the pillars of the workshop are the signal lights and command strips of the unmanned trolley, and the trolley can automatically avoid obstacles.

After receiving the reminder, Shao Zigong, an assembler of the pump truck, opened the MES system (production process execution management system of manufacturing enterprises) integrated in the WeChat of his mobile phone and clicked the "accept" button. By querying the order number of the model produced, he can clearly see each step of the process and wages.

"After this trip, I can earn more than 100 yuan." In Shao Zigong's view, "work is like playing a game", and every time you complete a task, you can get the corresponding reward. After a while, another pump truck was pulled by the automatic crawler, and after the reporter was a little distracted, he climbed onto the pump truck again and concentrated on tightening the screws.

The reporter noticed that each pump truck is equipped with a black box (Sany motion controller), which is the "secret weapon" developed by Sany Heavy Industry.

At present, Sany Group has more than 200,000 sets of equipment in the field, which transmit a large amount of data such as working conditions, locations, and equipment status through the black box. These data can be used to guide Sany's service improvement, R&D innovation, and market sales, and also form the industry's famous Sany "Excavator Index", which provides a basis for judging China's macroeconomic development trend.

According to reports, Sany has also built a *5658 localized industrial Internet platform in China - "Genyun". He Dongdong, CEO of Tree Root Internet, said that the "Root Cloud" platform uses emerging digital technologies to solve the pain points encountered by Chinese manufacturing enterprises in the construction of Internet of Things informatization, such as insufficient funds and lack of technology, and helps enterprises realize the transformation of intelligent manufacturing more quickly and conveniently.

"Tomorrow will be better"

At 5 o'clock in the morning, the sky is just bright, more than 10 brand-new pump trucks from the production line one after another, ready to accept the next process of testing, the test of qualified products will be sent to all over the world the next day.

For veteran employees like Peng Baixiong, such nights are both ordinary and precious.

Since 2012, China's construction machinery industry has undergone a long market adjustment, and the once beautiful Sany Heavy Industry seems to have fallen to the bottom overnight, and the sales of concrete machinery have fallen by 80%.

At a pre-shift meeting in 2012, Peng Baixiong noticed the chill of "winter" when he got the workshop production plan. "According to the sales plan at that time, the remaining inventory could not be cleared, which meant that we had no work to do."

Some employees left Trinity. In 2013, Peng Baixiong also received an "olive branch" from some companies to hire him at twice the current salary. But he chose to stay in Sany Heavy Industry, and the same choice was made by 60 brothers in the valve block machine processing team.

"I like to stay at Trinity." This honest and honest Lianyuan worker repeatedly repeated one word to reporters in his hometown accent: a sense of belonging.

In 2003, his child had eye surgery, and the company's labor union took the initiative to come to the door and gave him 8,000 yuan, which was his salary for more than 3 months at that time. "I'm grateful, so I can't leave when Trinity* needs me."

The company will eventually focus on the transformation of equipment intelligent manufacturing and industrial Internet. A year after being sent to the No. 18 plant, Peng Baixiong's team has a few more industry-leading CNC machine tools, and many robot colleagues have been ushered in one after another.

Since then, the company has successfully achieved intelligent and digital transformation, and its efficiency has increased by 3 times.

On February 29, 2008, Sany Heavy Industry Co., Ltd. held the annual "Trinity Day" to commend and reward employees who have contributed to the development of "Trinity" in the past year. At this "Trinity" party, Liang Wengen, chairman of Sany Group, also fulfilled the promise made five years ago and gave a reward of 100,000 yuan to each of the old employees who held the "Sany * brand". The holders of these "* cards" are 20 old employees who have been insisting on following Sany Heavy Industry since the establishment of the factory in 1994.

This scene moved Peng Baixiong very much. After New Year's Day in 2019, he held an unprecedented team annual meeting in a star-rated hotel, and specially invited the 60 brothers who took the initiative to stay that year to the scene and sang a song - "Tomorrow Will Be Better".