Intelligent production: The new trend of manufacturing from GengDa Group

In the production workshop of Ningbo Gengda Group Co., Ltd. (hereinafter referred to as "Gengda Group"), there is a strong sense of technology - more than 20 AGVs (automatic guided vehicles) operate flexibly in the vast workshop, transporting raw materials to the production line. After a series of processes, the formed bearing products are transported to the next workshop by AGV.

Founded in 1989, the Gengda Group focuses on ball bearings, tapered roller bearings, cylindrical roller bearings and precision machining. About 80% of its products are used in the automotive field. It is a national high-tech enterprise. At present, the company cooperates with many global automotive parts manufacturers and vehicle manufacturers.

Reduce costs and increase efficiency

The production workshop of the Gengda Group is clean and tidy, with several employees operating machines in front of display screens. New technologies such as the Internet of Things, the Internet, and big data have been integrated here to form the Weilai factory, which was fully put into use last year.

"At present, our super grinding production line integrates the five processes of surface grinding, centerless grinding, groove grinding, cleaning and assembly that were originally scattered in different workshops, which greatly shortens the production process and reduces logistics costs. Ten super grinding production lines have been put into use." Cui Xuebin, workshop director of the Weilai factory, told reporters."These devices are easy to operate, even simpler than manual labor. After systematic training, employees can quickly adapt to their new positions," Cui Xuebin added.

An AGV loaded with goods drove past the reporter. The intelligent warehousing and logistics system is the core of the Weilai factory of the Gengda group. The system covers the production process from material purchase and warehousing, production line supply, parts supply to finished product off-line, and can dispatch AGV robots, unmanned forklifts and other automated equipment in different scenarios and different areas.

Cui Xuebin introduced that with the support of product resource management system, workshop manufacturing execution system, product life cycle management and other systems, the Weilai factory has achieved full process interconnection and interoperability, achieving the goal of personnel efficiency and management informatization.

Manpower savings of 60%, production efficiency increased by 25%, energy utilization increased by more than 15%, operating costs and product defect rates decreased... In the more than one year since the full use of the Weilai factory, the results of cost reduction and efficiency improvement have been remarkable. At present, the Weilai factory has passed the acceptance of Ningbo digital workshop, provincial smart factory, and national smart manufacturing.

Green Empowerment

"New energy brake system bearings are the company's core products, mainly supplied to several models of brands such as Volkswagen, Mercedes-Benz, and Tesla." Qiu Xiaobiao, director of the manufacturing center of the Group, told reporters that the lightweight and low friction of the bearings can enable them to have higher speeds, longer life and lower energy consumption, which is also the main focus of Gengda Group.

The industry is developing rapidly, and product research and development is not stopping. In recent years, Gengda Group has successively invested more than 20 million yuan to build the engineering center laboratory, purchased various specifications of life test machines, high-speed test machines and other equipment, and continuously expanded the scope of detection, which has improved the technical strength of the laboratory and shortened the research and development cycle by more than 29%.

Gengda Group has transformed and upgraded its production in terms of resource utilization, supply chain and cooperation, corporate culture, corporate governance, and energy utilization, and has reduced carbon emissions by more than 4,900 tons. "In terms of resource utilization, we have achieved the recycling of cutting fluid and anti-rust oil, and most of the packaging boxes have been recycled; in terms of energy conservation, we began to install rooftop photovoltaic equipment in 2017, and about 10% of the electricity in the daily operation of the company comes from photovoltaic power generation; in terms of equipment upgrades, we have made extensive use of servo, frequency conversion and other technologies for equipment upgrades, while eliminating inefficient motors; in terms of energy management, we combine fine metering with lean production, continuously reduce the power consumption-to-output ratio, and improve energy utilization." Qiu Xiaobiao told reporters.

One post, multiple skills

Progress in the field of innovation requires talent. Gengda Group continues to introduce intelligent equipment, key projects, and sales talents, and has carried out in-depth cooperation with well-known universities to cultivate a talent echelon. The company will establish a doctoral innovation workstation in 2023. At present, the proportion of R&D personnel in Gengda Group has exceeded 24% of the total number of employees, and more than 90% of front-line employees have the ability to perform multiple functions in one position.

"The company has carried out school-enterprise cooperation, and the key technology research and development and industrialization projects of high-precision and long-life integrated nuts have been successful, and related products have been mass-produced." Qiu Xiaobiao told reporters.

In order to ensure employee satisfaction and the development of the company, Gengda Group comprehensively evaluates employees' skills, personality characteristics and interests, and strives to match each employee with his position and bring out their true potential. The company regularly evaluates employees' positions, promptly commends and rewards those who perform outstandingly, and makes appropriate position adjustments when necessary. In addition, the company also provides a series of welfare measures, such as full-staff provident funds, interest-free loans for employees, filial piety funds for parents, education funds for employees' children, and care funds for older employees, to ensure that employees can work with peace of mind.

Rong Weijun, chairman of the Gengda Group, told reporters that the company will continue to focus on product transformation and upgrading and the construction of future factories, relying on artificial intelligence, big data and 5G technology to achieve intelligent production, digital management and safe control. At the same time, the company will also increase its research and development and innovation efforts in new energy electric drive bearings, continuously improve customer satisfaction, and be committed to actively deploying in the global market to achieve the goal of "zero defects".

(Source: Economic Daily)