From 0 to 10 billion! Sany in Chongqing in just 29 months!

It took only one year for an enterprise to go into production from signing a contract to putting it into production.

This enterprise is Sany Heavy Machinery (Chongqing) Co., Ltd. (hereinafter referred to as "Sany Heavy Machinery"), which is also the first "lighthouse factory" built by "Sany Heavy Industry" in southwest China. From construction to production, it has set the fastest speed for the group's projects of the same volume to be put into operation.

At the beginning of this year, Sany Heavy Machinery set a new goal: to sprint 10 billion yuan in 2022! In other words, it is expected to take only 29 months to achieve the leap from "0" to "10 billion".

Why does Sany Heavy Machinery "run" so fast in Chongqing?

On March 31, upstream news reporters walked into Sany Heavy Machinery to explore the "password" for its high-quality development.

"Fast landing"From construction to production, it has created the fastest speed of "Sany Heavy Industry".

The Lighthouse Factory, known as the "most advanced factory in the world", is a model of smart factories. Digitalization, automation, and intelligence are its labels.

On the morning of March 31, when I walked into the factory, a "green picture" came into view: in the huge pool, schools of fish were leisurely; The pool is surrounded by greenery, and the tea house leisure area in the middle is convenient for workers to rest and entertain. The pool is flanked by waving robotic arms.

A view of the "Lighthouse Factory".

In this "garden factory", tens of thousands of excavators were produced in half a year last year, achieving sales of 6.81 billion yuan.

Back on July 1, 2020, the project was signed and landed in Chongqing Liangjiang New Area.

After less than three months of preparation, piling began in September of that year and was completed on schedule on June 30 of the following year. The construction of the 210,000-square-meter plant took only nine months.

"In terms of projects of the same size, this is the fastest project put into production by Sany Heavy Industry in the country." Deng Jinghui, general manager of Sany Heavy Machinery, recalled, "There is no single plant with such a large volume in other places. ”

What's the "secret" behind the fastest?

First of all, Chongqing was chosen because of Chongqing's "magnetic force":

Chongqing's developed automobile industry has strong industrial supporting capabilities, corresponding technical personnel, R & D personnel; The "road, water and rail" transportation network that connects the river to the sea can greatly reduce logistics costs. "Early construction, early production, early results!" Deng Jinghui said.

During the construction of the project, Deng Jinghui was deeply impressed by the "nanny" service of the local government: one month before the project was put into operation, about 2 kilometers of connecting road to the plant had not yet been opened. In order to ensure that the project was put into operation on schedule, Liangjiang New Area organized forces to "circle around" and "stare at the work", and the connecting road was successfully completed before the project was put into operation;

"A 'green channel' has been opened in the process of land acquisition and approval."

In Deng Jinghui's view, it is with these tailor-made full-process services that the project construction can be "fast".

"Fast production"On average, a large excavator rolls off the assembly line in 17.3 minutes

Sany Heavy Industry has 3 excavator factories in China. Different from Jiangsu and Shanghai, the Chongqing factory has a more complete range of products: producing a total of 11 large, medium and small excavators.

The "fast" of Sany Heavy Machinery is also reflected in the production efficiency: when the total assembly line is at full capacity, a large excavator can be rolled off the assembly line every 17.3 minutes on average.

Workers assembling the excavator "arm"

At the entrance of the "Lighthouse Factory" production line, four robots are running quickly online to weld the excavator stick together. This kind of "four-machine linkage" is rare in the world due to its high coordination requirements and difficult development.

Robot welding emits blue sparks

"The automatic welding rate of the robot is as high as 95%, and the UT pass rate is close to 100%." Chen Gongqiang, deputy director of the Component Technology Institute of Sany Heavy Machinery Technology Institute, said that this "black technology" solves a major pain point: the welding seam operation space is narrow and it is difficult to achieve a suitable welding angle.

In fact, there are still a lot of "black technologies" of Sany Heavy Machinery.

For example, in the automated bending island, with the support of 3D vision technology, the robot can accurately grasp the material and automatically operate the bending and online inspection, and the product qualification rate can reach 100%.

Under the linkage of various systems, Sany Heavy Machinery can intelligently schedule production according to market sales, inventory and equipment capacity, and then issue instructions to the central control system. After receiving the instruction, the equipment on the production line will automatically respond, independently loading and unloading, distribution, welding, etc., until the assembly is completed and walks off the production line.

"It can achieve the effect of 'a steel plate goes in, and an excavator comes out'." Chen Gongqiang said that the current factory automation rate has reached 80%, saving more than 50% of labor.

It is understood that the "lighthouse factory" has an investment of about 2 billion yuan, mainly producing 11 large, medium and small excavators of 55 tons and below, with a design capacity of 93 units / day and 28,800 units / year.

"According to the goal set for the whole year, this year will sprint 10 billion yuan." Deng Jinghui is hopeful about this goal.

"Fast chain replenishment"Several supporting suppliers have decided to build factories nearby

The excavator is assembled off the assembly line and is integrated by numerous supporting components.

In the supply chain of Sany Heavy Industry, there are more than 270 large and small supporting enterprises, including hundreds of major supporting enterprises. However, most of these enterprises are concentrated in the eastern coastal provinces and cities such as Shanghai, Jiangsu, Zhejiang, and Shandong.

"In order to shorten the distance between supply and supply, the supply chain will gradually be transferred to Chongqing and its surroundings." Deng Jinghui said, for example, that some suppliers of small mechanical processing parts are far away in Yangzhou, Jiangsu, and the logistics cost alone is a large number.

At present, Sany Heavy Machinery is trying to cooperate with a company a few kilometers away, and the comprehensive cost has been reduced by 8%.

Following the commissioning of Sany Heavy Machinery, seven or eight supporting suppliers have decided to build factories in Chongqing to produce small parts such as wire seats, lamps, and pipe clamps.

For example, a coastal gasket company has acquired land in Changshou to prepare to build a factory, and a sponge manufacturer has built a factory in Chongqing.

In order to ensure that the supply chain does not "drop the chain", Sany Heavy Machinery has adopted two major strategies: one is to mobilize original suppliers to build factories nearby, and the other is to rematch suppliers in Chongqing and its surroundings.

"I hope that more than 20 core suppliers will gather in Chongqing."

Deng Jinghui roughly calculated that if the annual purchase amount of 5 billion yuan is calculated, the local supporting rate will reach 70%, which is expected to reduce the cost of more than 150 million yuan for the enterprise.

When Deng Jinghui matched engine suppliers in Chongqing, he had already matched a powerful enterprise to provide him with a number of core components, and it is expected that there will be substantial cooperation next year.

"Fast Layout""Made in Chongqing" excavators are to be sold all over the world

Sany heavy industry excavator can be described as a "trump card" product, with a market share of more than 30% for 11 models, and some even reach 40%. At present, the market positioning of the Chongqing production plant has been clear: the domestic market is facing the southwest and northwest, and the foreign market is facing Southeast Asia, Central Asia and even Europe.

"Made in Chongqing" excavator

On December 3 last year, the China-Laos Railway was officially opened to traffic. The freight time from Chongqing to Laos will be shortened to about 3 days, and the goods can also be transferred to Thailand or Vietnam through this railway, which greatly reduces the transportation cost of enterprises and greatly improves the freight efficiency.

"Laos is in greater demandMedium-sized excavators。 Deng Jinghui told reporters that the relevant work of exporting to Laos is currently being started, and it is expected to be determined in the second half of the year at the earliest.

He calculated an account: the export of medium-sized excavators from Shanghai to Laos must first be transported to Bangkok, Thailand for landing, and then transferred to Laos by rail or road, which will take one month. In addition to the time cost, the logistics cost from Chongqing to Laos can be saved by about 45%.

During the interview, Deng Jinghui sent a task to the accompanying Chinese cadres: If the export to Europe takes the China-Europe Express (Yuxinou), can the transportation cost be reduced? Calculate the data as soon as possible and come up with a plan.

At the same time, in view of market positioning, the Chongqing factory is also laying out R&D capabilities. According to the plan, the framework of the entire new product research institute will be put together this year, and we are currently recruiting.

"R&D will be carried out based on the conditions of construction soil quality and other conditions in the market area." Wang Shengqiao, director of the Institute of Intelligent Manufacturing, said for example, that in the future, it may also be developed for engines, mufflers, radiators, etc., and the entire research institute is still being approved, and the investment is also being calculated.

Reporter's NotesA vivid illustration of building an advanced manufacturing hub

The "Chongqing speed" run by Sany Heavy Machinery is the epitome of Chongqing's promotion of high-quality development.

In recent years, Chongqing has continued to make efforts to optimize the business environment in an all-round way. In the interview, Deng Jinghui said a sentence: "In Chongqing, enterprises have problems, and the government's response speed is really fast!" ”

A good business environment is productivity and competitiveness.

In the process of construction of key projects, the government focuses on the project, stares at the project, provides "one enterprise, one policy" and "one matter, one discussion" services, and opens up a "green channel" to solve the "difficulties" and "stuck points", so that enterprises can fully feel the government's determination to do things and the warmth of service.

The innovation-driven development strategic action plan led by big data and intelligence has become the main driving force for Chongqing's high-quality economic development. A large excavator off the assembly line in an average of 17.3 minutes is the most vivid case.

The leap from "0" to "10 billion" has become a vivid annotation for Chongqing to accelerate the construction of an important national advanced manufacturing center.

Relying on Chongqing's existing industrial base, Sany Heavy Machinery reorganizes the supply chain according to local conditions, and achieves cost reduction and efficiency increase by clustering chains: only small gasket components can save 8% of the cost.

Deng Jinghui's "logistics ledger" also calculated the "dividend" of Chongqing's opening up.

The inland hinterland has become an open highland, Chongqing has been connected to the river and the sea to embrace the world, and the "Made in Chongqing" excavator has several international channels to the world. The "lighthouse factory" represented by Sany Heavy Machinery will undoubtedly set up a new "lighthouse" for "Chongqing Intelligent Manufacturing" and "illuminate" the transformation and upgrading of the manufacturing industry.

Content transferred from: Upstream News

Upstream News Reporter Guo Faxiang Sun Qiongying Video Editor He Chuang Editor/Su Hang