The importance of cutting tools and their management to the automobile manufacturing industry and the manufacturing cost of production efficiency are causing more and more attention from top management of automobile manufacturing enterprises. In today's fierce market competition, which auto manufacturing company can better manage its tools, can more effectively improve production efficiency and reduce manufacturing costs, will put the competition in a favorable position. How to continuously explore and innovate, carry out effective tool management and achieve win-win results, has become a topic of discussion among tool suppliers in the automotive industry.
The impact of tools and their management on production efficiency
The automotive industry's production process involves a large number of machining, especially metal cutting. The workpiece size, precision and surface topography are all related to the tool. The tool performance and quality directly affect the smooth processing of the required qualified products, which affects the processing efficiency of the processing cycle. Modern automobile manufacturing uses a large number of high-speed cutting, all kinds of super-hard tools and various types of standard and non-standard tools. Whether the tool can meet the requirements of high-speed cutting, how the tool life and the frequency of tool change will directly affect the starting rate of the production line, and Whether to ensure quality on time and to adjust or repair the tool to the production line will directly affect whether the production can continue normally.
Since the automobile industry has adopted a large number of production lines, the production of the upper process directly affects the next process. Especially because of the continuous implementation of lean production, there are few inter-products and buffers. In order to improve production efficiency and reduce production costs, a large number of combined tools and Non-standard tools, therefore, a key tool, especially non-standard tools, if not supplied on time, will cause the entire machining line to be discontinued. If the company does not have emergency measures or can not respond quickly, it may cause the assembly line of the assembly or even the assembly line of the automobile to be discontinued.
Tool and its management impact on manufacturing costs
Tool and its management costs Auto parts manufacturing costs occupy a very important part. Under normal circumstances, an annual output of hundreds of thousands of engine factories, the annual tool costs may reach tens of millions or even hundreds of millions of yuan. In addition, the tool knives and accessories have a large amount of liquidity, so reducing tool costs has become a very important, urgent and difficult task for enterprises. The reduction of tool costs is closely related to the adoption of new tools, new processes, new technologies, and new materials. It is also closely related to a series of tool management tasks such as tool procurement, logistics, adjustment, grinding, tool quality control, and tool optimization.
High tool management level makes it possible to carry out good tool cost control, which not only ensures that the production line meets the required tools in time, but also keeps the quantity of inventory tools at the minimum necessary level, so that the liquidity occupation and its financial expenses are minimized. At the same time, it can continuously carry out tool optimization, reduce cost and increase efficiency, and can make timely and rapid response when abnormal tool consumption occurs, to ensure normal production.
New tool performance, longevity and purchase price have the greatest impact on tooling costs, while the number of regrindable tools, the number of regrinds and the cost of grinding have a significant impact on the total cost of the tool. At the same time, we also pay attention to the relationship between disposable equipment tool investment and long-term tool consumption. Some projects have the potential to save equipment investment in project planning, but use expensive tools or unreasonable cutting parameters, resulting in short tool life and long-term high-cost tool consumption.
Regarding the cost of the tool, it is more important to look at the total tool consumption cost. It is more important to look at the tool cost of the single-piece machining product. When comparing the tool and management cost of each enterprise, it should also compare the tool cost of the similar product. What percentage of the total manufacturing cost of tooling costs is normal? What is the current level of advanced tool consumption in the automotive industry? There is no authoritative data yet.
As a general rule in the tool industry, tool costs account for 3% to 5% of the total machining manufacturing costs. But in fact, the amount of tool consumption is related to many factors, and specific analysis is needed. Looking at the total tool consumption costs, it is more important to look at the cost of tooling for single-piece product processing. When comparing the tooling of each company and its management costs, it should also compare the tool cost of processing a single piece of similar products.
In any case, the cost of tooling in the automotive industry has a significant impact on manufacturing costs, requiring strict cost control, and tooling can be significantly reduced by improving tool management and optimizing tools.
Current status of tool management in the automotive industry
At present, domestic and foreign automobile manufacturing enterprises have different management mode management methods for tool management, and their practices are different, mainly in the following three categories:
1, the traditional mode
The traditional model does not have a complete concept of tool management. The business related to the tool belongs to different departments within the enterprise and is managed separately. Slightly larger machinery, gearboxes, axles and other mechanical processing plants often have tools or tool workshops, but their functions are mainly tool sharpening or tooling repair and tool library or tool library management; tool procurement belongs to the purchasing department (section ), but the tool purchase application is required by the use department; the product machine shop has a tool engineer or technician, whose task is to solve the problem of on-site machining related to the tool, and to propose the tool purchase request and the tool minimum. The inventory is responsible; the tool is used and adjusted by the production workshop; the technical work such as tool optimization and improvement is handled by the technical department (process department).
The work efficiency is low, the procurement cycle is long, and the tool inventory cost is high. The traditional model has common problems. In order to prevent the serious consequences of the production line stoppage caused by the lack of tool supply due to the large number of procurement links and long cycle time, the company has to greatly increase the minimum inventory setting of the tool, which makes the tool inventory increase greatly and takes up a lot of flow. Capital and financial costs are heavy. In addition, it should be noted that the cost of the tool single piece product calculated in this traditional mode often does not really reflect the cost of tooling the actual single piece of tool processing, and there may be other departments that spend human and material costs on the tool.
2, outsourcing management mode
Tool management involves tool selection, testing, purchasing, adjustment, sharpening, repair, inventory setting and control, tool life control, production process problem tracking analysis and tool optimization.
With the development of modern large-scale production methods, enterprises respond quickly to market competition and reduce manufacturing cost requirements. It is required to be able to manage all aspects of tooling in an integrated manner, and then a unified department can then use social resources for management. This allows companies to focus more on their core business, focusing on quality control of their product development, production and technology development.
Tool management, a specialized technical resource support work, is outsourced as a supportive work, resource optimization is configured, competitive advantage is maintained, and cost control is effectively realized to achieve higher efficiency, better quality, and lower cost. In the emergence of the management model of tool outsourcing management.
Tool outsourcing management first appeared in North American automakers. With the establishment of many joint venture countries in the country's reform and opening up, the concept of tool management and its outsourcing management model also emerged. Now, a considerable number of factories in China have adopted or are beginning to adopt this new tool management mode.
3, Toyota mode
Toyota Motor Corporation of Japan has been a lean production mode advocate, and its tool management also has its own unique approach.
Toyota has a unified management of the tools, and its management department has a special tool management organization and a central tool magazine. For some factories, the common tool cutters are used in a wide range of tools, and the unified purchase order pull tool supply is implemented. One of the important features of many tools is that the library work is performed by the supplier, and the tool supplier makes an immediate request based on the tool order. Reaction and on-site technical support for on-site service of tool use.
Toyota's central tool management organization also coordinated the guidance of each subsidiary's tool procurement. The negotiation of the tool price between the subsidiaries and the tool supplier and the tool price information obtained by the company can be obtained and beneficially guided by the central tool management organization. Earning offers can be shared by other affiliates. At the same time, because many knives have the library work to be handed over to the supplier, the liquidity of the tool inventory is reduced, and the overall tool cost is greatly reduced.
Tool management, automotive industry development trend
More and more auto manufacturers are trying to improve tool management, explore new tool management modes or management approaches, and try to improve tool performance life and improve production efficiency through effective tool management and tool optimization process. Significantly reduce tool management costs and tool consumption costs.
Tool integration management will be further developed, and the theory of tool outsourcing management will be further explored. Based on the original 5-level tool management, a new tool management mode is developed which is more conducive to improving work efficiency and reducing tool cost. More companies will strengthen the integrated management of tools, and will unify the work related to tool procurement, logistics, inventory, adjustment, sharpening, repair, tool optimization and improvement, and organize, manage and coordinate with the unified department to improve Work efficiency, reduce management tool consumption costs, and enhance technical support for production frontline services.
Different levels of tool management will have demand and development. With the development of logistics and other industries such as tool grinding and tool coating, the trend of outsourcing of tool sharpening, repair and inventory management is gradually increasing. Some automakers may still control their tooling work, tool optimization, etc., while outsourcing tool sharpening, adjustment, inventory management, etc., and seeking on-site technical support from some tool suppliers. This will not only enjoy the many benefits of tool outsourcing management, but also reduce the excessive dependence on tool management outsourcing suppliers.
Some big auto groups may set up tool management related platforms at the group level like Toyota Motor Corporation, but their working methods will improve. They will further strengthen the planning and coordination of the tool management work of the factory or subsidiary of the group, including the guidance and coordination of the tool outsourcing management work of the relevant subsidiaries; strengthen the leadership of the tool optimization work, and implement unified procurement for part of the large-scale tool, pull-type Tool supply; the company shares tool technology, procurement information and experience in tool optimization and tool problem solving. Due to the Group's unified procurement, the purchase volume is large and stable, and it is possible to establish a better long-term partnership with the tool supplier to obtain a lower purchase price.
In the tool management work, the automobile manufacturing enterprises will invest more efforts to seek the localization of tool supply and seek more real-time on-site technical support. In order to shorten the tooling time and improve the response speed and greatly reduce the tool cost, the automobile manufacturing enterprise will work with the tool supplier to establish a rapid response mechanism for the tool early warning mechanism and strengthen the tool optimization work.
Conclusion
At present, almost all the famous tool knives and accessories companies and their products have entered the country. Many companies have invested in setting up factories to provide various technical support services for domestic automobile manufacturing enterprises. Domestic tool manufacturers are also working hard to improve the level of tool design, manufacturing sharpening and coating technology, in order to adapt to the large-scale use of CNC machining equipment in the domestic automotive industry, and continue to develop high-speed, high-precision machining requirements. All of this provides a good external condition for the automotive industry to further improve the management of tool applications.
Regardless of whether the automakers themselves have integrated tool management, outsourced tool management, or a combination of tool management, they will make full use of social resources. The inevitable result of industrialization of economic globalization, and the inevitable trend of development of tool management.
Automobile manufacturing enterprises will establish long-term cooperative partnership with various tool manufacturing service enterprises. Based on computer information technology, the tool management software tool information database will further develop communication production and demand, customers and suppliers, problems and solutions. Interplay.
With the establishment of some professional tool development, tool manufacturing, tool grinding and coating company and its extensive distribution service network, the tool management of the automobile industry will be more strongly supported. Other auxiliary tools such as various new tool holder systems, tool adjustment, testing equipment, tool balancing systems and their suppliers will also develop domestically with the rapid development of tool management needs in the automotive industry, and provide effective services to the automotive industry. With support.
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