1. Lean manufacturing is the cornerstone of intelligent manufacturing

From lean, automation to intelligent manufacturing, lean management has made Toyota’s upgrade “a matter of course”. In the next ten years, China’s manufacturing industry will focus on the deep integration of industrialization and industrialization, and focus on intelligent manufacturing. In this process, various resources must be developed in a balanced manner from all directions, and the parallel promotion strategy of “industry 2.0 supplementary courses, industry 3.0 popularization, and industry 4.0 demonstration” must be implemented. Whether it is transformation and upgrading, deep integration of industrialization and industrialization, or intelligent manufacturing, lean management is an important link that cannot be ignored.

Lean is listed by Germany as one of the four major modules that constitute the future smart factory, and it is also the basis and guarantee for China’s manufacturing to realize the 2025 plan and accelerate transformation and upgrading.

From the perspective of intelligent manufacturing, it is a human-machine integrated intelligent system composed of intelligent machines and human experts, which can carry out intelligent activities during the manufacturing process, such as analysis, reasoning, judgment, conception and decision-making. It updates the concept of manufacturing automation and extends it to flexibility, intelligence and high integration. It is not difficult to see that it has the functions of customization, personalization, intelligent analysis, forecasting and management.

The basis of intelligent manufacturing is lean, which fundamentally solves the “quick response” in terms of quality, cost, and efficiency, and achieves customized and personalized manufacturing.

Lean management takes customers as the core, and drives the realization of intelligent manufacturing through R&D, manufacturing, quality, and supply chain management. According to industrial data, the profit growth rate of industrial enterprises is declining. There are three reasons: slow product sales growth, rising costs faster than sales growth, and lower prices squeeze profit margins. Lean management wins by responding quickly and improving production efficiency. Reduce costs and maximize enterprise value.

Intelligent manufacturing can provide sufficient guarantee for lean management, making possible things that were previously considered impossible in the production process, making things that were difficult before easy, and making things that were not possible before possible! Therefore, it is necessary to understand intelligence for lean production At the same time, it is also necessary to understand that lean is the source of production efficiency and quality.

From lean production to intelligent manufacturing, a new intelligent industrial production model marked by highly digitalized, networked, and machine self-organization will be established, and the realization of Made in China 2025 will be realized.

Second, the misunderstanding of intelligent manufacturing

Many enterprises attach great importance to the automation transformation of bottleneck stations or stations that consume more labor, and promote “machine substitution”. Although this method can reduce labor and improve the efficiency of a single station, it has little significance for improving the overall efficiency of the production line, and often transfers the bottleneck process to other stations.

The correct way is to optimize the production line as a whole based on the concept of industrial engineering, using methods such as value stream mapping, according to the type of product produced, output, batch size, manufacturing process, production capacity, production tempo, and WIP logistics transmission mode; at the same time, From the perspective of automatic processing and assembly, the manufacturing process is optimized to reduce the difficulty of automatic transformation and meet the production and assembly of various variant products as much as possible. For example, a container manufacturing company served by the e-works consulting team optimized the original plate cutting → roller forming → panel spot welding → automatic welding process through process optimization when producing container side wall panels and roof panels. Changing the original longitudinal welding seam into horizontal welding seam, the process is optimized to weld the whole plate first and then form it, which not only reduces the length of the welding seam, but also facilitates automatic transformation, and successfully realizes the multi-process continuous automation from steel uncoiling to forming . Another rail transit door manufacturer that the e-works consulting team has served for a long time optimized the layout of the workshop based on the “one-flow” principle of lean production during automation transformation, and balanced the tempo to ensure the balance of the entire production system after the completion of the automation transformation. , Reduce the distance of transportation, and eliminate the waste caused by production waiting and transportation to the greatest extent.

What are the misunderstandings of intelligent manufacturing?

All the above content is all the introduction about intelligent manufacturing brought to you by the editor this time. If you want to know more about it, you may wish to explore it on our website or on Baidu or Google.