Heavy truck high-quality "big tooth" is made like this

October 9, 2017, from Shanxi Province, the quality of the General Assembly to upload news - China National Heavy Duty Truck Group Co., Ltd. Datong Gear won the second session of the Shanxi Province Quality Award, for "big tooth" and, this is a great honor.

Shanxi Quality Award

Datong Gear Co., Ltd. was awarded the Shanxi Provincial Quality Award, benefiting from the influence and value of “Sinotruk” brand and widespread market recognition; benefiting from the continuous improvement of multi-level quality management concepts and methods of the entire company, and the full-scale quality awareness of the company. The continuous improvement of operations and the successful implementation of "excellent engineering".

Over the years, Datong Gear Co., Ltd. has been adhering to the corporate tenet of “persevering people as the foundation, honesty and reliability of China National Heavy Duty Truck” and the concept of “recruiting fine products and striving to be the first”, and firmly establishes quality as the brand's awareness among all employees and is unwavering. Taking the fine road of “adjusting structure, improving quality, creating brand”, through internal innovation and various advanced quality management methods, we have formed a quality management model with Datong Gear Company's characteristics, demonstrating that “using quality products to create quality products, using quality products Contributing to social values.

Halfway to the "king of the gearbox"

The predecessor of Datong Gear was Datong Integrated Machine Tool Factory which was built in 1958. At that time, the main products were potted machines and centrifugal pumps. In 1963, it was renamed as Datong Agricultural Machinery Parts Factory. It mainly produced tractor accessories and cast iron pipes. At this time, it was only slightly detached from the truck.

China National Heavy Duty Group Datong Gear Co., Ltd.

In 1964, the factory was renamed as Datong Gear Factory. At that time, it mainly produced heavy-duty vehicle gearboxes, engine gears, and car transfer gears. In the late 1980s and early 1990s, it officially entered the gearbox business. In 1997, Datong Gear Factory completed the reform of corporatization and became Shanxi Datong Gear Group Co., Ltd., which was under the jurisdiction of Shanxi State-owned Assets Co., Ltd. After the corporatization reform, Shanxi Datong Gear Group Co., Ltd. did not give up its predecessor. In 1998, the company was jointly listed with Taiyuan Heavy Machinery Group and established Taiyuan Heavy Industry Co., Ltd. Datong Gear Division, which mainly produces light, medium and heavy-duty automobile gearboxes, engine gears and other products.

In November 2008, Shanxi Datong Gear Group Co., Ltd. became a wholly-owned subsidiary of China National Heavy Duty Truck and was renamed as China National Heavy Duty Truck Group Datong Gear Co., Ltd. For large teeth, this was a landmark event that marked a large tooth. It has entered a new era of leap-forward development.

Datong Gear Co., Ltd. is located in Datong City Equipment Manufacturing Industry Park. It covers an area of ​​917 mu. Through the introduction of advanced technology of Nissan Diesel, it has formed an annual production capacity of 220,000 sets of heavy-duty automobile gearboxes and 1.6 million pieces of automobile engine gears. At present, Datong Gear has already had 5 to 16 gears, 7 gears and 18 series of various types of automotive gearboxes and hundreds of products. It has achieved full coverage of commercial vehicle gearboxes, and the export products have obtained the quality of British JCB and Cummins Inc. Awards; gearbox products won the Dongfeng Corporation, Futian company quality award, is the only one with the Japanese, European, American Department of the three major technical platforms and full synchronizer, dual intermediate shaft, planetary mechanism, AMT and other technical routes Box R & D and manufacturing companies.

Datong Gear Company Shapes New Quality Sample

Walking into Datong Gear Co., Ltd., located in the Datong City Equipment Manufacturing Industry Park, clean and tidy workshops show modern elements everywhere.

Makino processing center flexible box automatic production line, shaft grinding processing automatic production line, Germany Hurth razor mill, Switzerland's Lei Haoer and other advanced equipment readily available, which makes "big tooth made" will not lose at birth "start line "on.

China Heavy Truck Transmission Line

In November 2008, Datong Gear Company formally joined the CNHTC Group family. With this Dongfeng, the company further improved its product chain and set up the “Automotive Transmission Engineering Laboratory” of Datong Gear, a state-level engineering laboratory. This is the most authoritative organization for transmission inspection of commercial vehicles and is the cradle of new transmission technologies and products. It can not only be completed. Internal product development, and can adapt the external product development, provide technical support and services.

Into the laboratory, you can see all test bench information on the monitoring screen, fatigue test bench, fork bench, synchronizer performance test bench, static bending test bench, gas assist test bench, high speed lubrication test bench, power take-off Fatigue test bench, temperature test bench... Each data on the gearbox is intuitively visible.

The synchronizer performance test bench can simulate the situation of synchronizers in various environments. The current synchronizer has been tested for 150,000 operations and the planned number is 500,000. As long as it can pass, the gearbox can be easily performed in any environment. .

Datong Gear Co., Ltd. implements the "excellent engineering" strategy, highlights the principle of "quality first" in the production process, emphasizes the stability of process control, and has any situations or links that conflict with quality objectives, and is considered as touching the "quality red line". Ordered deadline to resolve. Follow problem-oriented and performance-oriented principles to identify problems and improve product consistency and reliability.

A complete quality traceability system is a powerful guarantee for building quality projects. Each processing department establishes a permanent logo registration account for self-processed products, clearly identifies the product name, supplier code, processing batch, etc., and prints the serial number symbolizing the identity of the workpiece on the surface of the workpiece. The Assembly Department fills in the “Assembly Quality Record Card” as required and enters the ERP system to scan the two-dimensional code to determine the unique identity and nameplate identification for each off-line transmission assembly.

Responsible engineer team strength

The team is nimble and the product quality comes from the superposition of everyone's efforts. Datong Gear Co., Ltd. strives for survival by quality, allows its employees to integrate into a standardized quality management model, and then uses this model to become habitual and moves toward a national quality sample.

In recent years, Datong Gear Co., Ltd. has firmly established the awareness of quality as a brand among all employees. Through the implementation of advanced quality management methods such as “excellent engineering”, “one meeting” and “responsibility engineer system”, Datong Gear has explored and developed quality management with big teeth characteristics. mode.

China National Heavy Duty Truck Quality Management Co., Ltd. Although the “responsible engineer” system was not initially implemented at Datong Gear, it has been perfectly represented here.

In the impression, the traditional workshop production uses the workshop and the team as the cells. In comparison, the “responsible engineer” system enables the flat management of the team to be more flexible.

In 2014, Datong Gear Co., Ltd. began to implement the “responsible engineer” system. The teams consisted of team leader, process engineering technicians, operators, and maintenance workers with complementary advantages. Responsible engineers are all recruited from excellent technical personnel or experienced team leaders. Today, the original Datong Gear Company's original 10 processing divisions of 101 teams are integrated into 41 field duty division teams. The 203 team leaders and banners are integrated into 41 field responsibility engineers and 43 assistant responsibility engineers.

The numbers are intuitive and the effect is obvious. Responsible engineers have the right to choose the best team, and those with high technical skills will be "famous for the right", and "more than learning to catch up" with a strong atmosphere, and the benefits will naturally be high.

First, the level of technology has improved. It has created better conditions for technical talents to bring their own advantages into play, and achieved the docking, collision, and correction of the technological principles and practical work.

Second, the equipment failure rate is reduced. The maintenance team entered the team, improved equipment support capabilities, turned fault maintenance into routine maintenance, and greatly reduced equipment downtime.

Third, the team's combat effectiveness increased. The team leaders, engineering technicians, operators, and maintenance workers combine the management teams to achieve complementary advantages, complement each other, and collaborate with each other.

The data for 2016 shows that “responsible engineers” have increased the production efficiency of the company by 12%-20%, and the product quality of 56 production lines and 58 engine gears has reached “zero defects”. “The responsibility engineer system, just like the gears and transmission products we produce, has played a role in gearing up the quality of employees.” Wu Zhenghe, Chairman of Datong Gear Co., has deep feelings.

Turn employees into real stars

In order to fully motivate the employees, Datong Gear Co., Ltd. has included training and establishing advanced models as its annual work targets, and has formed a method for employees to conduct self-recommendation (recommended) and comprehensive evaluation of labor models at the end of each year.

Who can become typical

The focus is on the selection of technology, production, and marketing, especially the emphasis on excavation of highly skilled personnel. Various types of selection projects are set up, and annual position models for production, quality, technology, efficiency, marketing, management, and service assurance are set up.

The selection process is "demanding"

From the “Star of the Week” to the selection of model workers, employees must be recommended by themselves, recommended by grassroots units, publicized by advanced deeds, approved by departmental employees, the company’s candidate deeds, democratic voting, and year-end appraisal and appraisal.

The "Star of the Week" chooses trees. Each week, the units selected candidates for the “Star of the Week” in the department through democratic recommendation and recognition evaluation; the company publicized the deeds of the candidates and organized online voting, selecting the “star of the week”.

Develop a self-reported model. Launched in 2005, it has changed from the initial year-end election tree to a quarterly self-recommendation (recommendation). The candidate must come from the "star of the week."

In 2016, Datong Gear Co., Ltd. recommended a total of 90 candidates in the four quarters, and finally selected 10 model workers. Among them, Xu Yucheng of the Synchronizer Processing Department became the winner of the National May 1st Labour Medal, Li Jianjun of the Shaft Processing Department became the model worker of China National Heavy Duty Truck Group, and Wang Zhushan of the box processing department became the “moving the heavy truck person”. At present, Datong Gear has two national labor models, one national May 1 Labor Medal winner, and one National Labor Model Worker in the machinery industry. Many others have been awarded Provincial Labor Model Honors and Provincial May Day Labor Medals.

Keeping employees at the forefront of innovation

In Datong Gear's workshop, "Xu Liang's work method," Xia Kangkang's rapid change of mode law, "cost control benchmarking team" ... innovation benchmark brand can be seen everywhere, thanks to the company's "all staff innovation and wonderful two things" activities Carry out.

In 2015, Datong Gear Co., Ltd. began to implement "two things that are wonderful for all employees." At the beginning of the year, he went to the chairman of the board and went down to the ordinary staff. Everyone established the goal of “two things”, based on the position to seek new breakthroughs, and handed out innovative questionnaires by the end of the year to allow “everyone to become the main body of innovation”.

Continuously improve the added value and brand influence of products

The company adopts quarterly tracking and annual general incentive methods to promote activities, and uses the “excellent, good, qualified, and unqualified” grades to score and respond to different incentives. At present, the "two things of great innovation" has become an effective method for Datong Gear Company to solve technical problems. In 2016, the company completed a total of 3,656 projects. In the year-end appraisal work, 116 innovation initiatives concerning quality improvement, market breakthrough, and quality project promotion have achieved high levels.

At the same time, at the same time, the company also retained the tradition of teachers and teachers - senior technicians with technicians, technicians with senior workers, and senior workers with junior workers. The combination of traditional and innovative talent cultivation models allows Datong Gear to be at the forefront of innovation.

Through technological innovation, the company has continuously improved the value added of its products and its brand influence. The company has obtained 97 patents, including 24 invention patents, 49 utility patents, and 24 appearance patents. The QC team also achieved remarkable results. From 2015 to 2017, it was awarded the first prize for the QC results of the China Machinery Industry Quality Management Association, 4 second prizes and 6 third prizes.

Staff Innovation Platform: "Master Studio"

Master, the words that make people respectful. In Datong Gear Company, the “master workshop” named after the master of skills is like the Whampoa Military Academy, and it constantly trains talents. At Datong Gear, the masters have countless contributions.

The “Master Studio” is the position to overcome production problems and is also the cradle of skilled talents. At present, Datong Gear has a total of four provincial-level employee innovation studios and two city-level innovation studios. In 2016, it tackled more than 280 production problems.

The "Master Studios" each assume the goals and tasks, and are independent and cooperating with each other. Liu Qi, the master laboratories of the National Labor Model Liu Qi and Bi Yanjun, is responsible for solving problems in the external market of transmissions, on-site quality improvement, and transmission quality innovation. The mission of the upgrade, the HW19710 transmission range file cylinder failure improvement project, won the first prize of the QC results held by the National Machinery Industry Federation. Xu Yucheng’s Master Studio of Skills is an inter-departmental studio. In the past few years, it has completed 61 types of improvement projects and saved more than one million yuan.

The masters strive to make more young people become talented. In the pre-class meeting and the work site, the masters will conduct one-on-one training; in the work area, they will combine equipment, facilities, etc. to carry out training in operation procedures and daily maintenance; they translate experience into text, and Liu Qi prepares the assembly basis. Knowledge, "anti-error law" and "application of PDCA cycle" have become necessary courses for new employee training.

The results are numerous, not only in Huizhong, but also outside. The "Master Studio" actively promoted employees to go global. In 2016, they declared 22 outstanding achievements in provincial-level “five small” innovations and achieved brilliant results.

Today's quality, tomorrow's market. In the future development, Datong gear people will implement the requirements of the party's Nineteenth Congress and the requirements of “promoting the transformation of Chinese manufacturing to China, the transformation of China’s speed to China’s quality, and the transition of Chinese products to Chinese brands” and continue to meet the requirements of the “world standard”. , China's first quality goal struggling to advance, with scientific development, innovation and development, beyond development, green development of new performance, for "China Heavy Duty" brand glory, in the domestic and international markets to display "Made in China" a good image!

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