From lean manufacturing model to intelligent manuf

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From lean manufacturing model to intelligent manufacturing model, how does Nantong COSCO Shipping Kawasaki do it

Editor's note: China's manufacturing industry has entered a critical period of "climbing over barriers". How to leap from the middle and low end of the value chain to the high end, accelerate transformation and upgrading, innovate and develop, improve quality and efficiency, and realize the transformation from large to strong has attracted much attention. Recently, China Electronics News went deep into Ningbo, Hangzhou, Shanghai, Nantong and other places to interview representative enterprises such as automobile manufacturing, parts manufacturing, aircraft manufacturing, shipbuilding and so on, summarize the experience and practices of these enterprises in the 40 years of reform and opening up, and especially launched a series of reports on the "40 years of development of manufacturing reform and opening up". This article is the fifth in a series of reports

"stop-5 second danger prediction", in Nantong COSCO Shipping Kawasaki Shipbuilding Engineering Co., Ltd. (hereinafter referred to as Nantong COSCO Shipping Kawasaki), the words "everyone is required to stop for 5 seconds before starting each operation and taking each action to think about the potential safety hazards of such actions and how to do it safely" are embroidered on the cuffs of each employee's work clothes. It is precisely because the management of every link of the enterprise pursues perfection, so Nantong COSCO Shipping Kawasaki shipyard has created a model of "Chinese style lean management". In fact, Nantong COSCO Shipping Kawasaki shipyard has been innovating and developing in the years of reform and opening up. It is not only a model of "Chinese style lean management" in the shipbuilding industry, but also a model of "international economic exchange and cooperation", "intelligent manufacturing" and many other aspects

from lean manufacturing to intelligent manufacturing

compared with foreign enterprises, the manufacturing efficiency of Chinese shipbuilding enterprises is often short board. How to shorten the manufacturing cycle, improve efficiency and achieve high-quality development is the desire of many shipbuilding enterprises

Nantong COSCO Shipping Kawasaki is a large modern shipbuilding enterprise jointly established by the former China Ocean Shipping (Group) Corporation, one of the predecessor of COSCO Shipping Group, and Japan Kawasaki Heavy Industry Co., Ltd. in the form of half shares at the end of 1995. Since its establishment, through "sharing, digestion, absorption and re innovation", it has formed a Chinese style lean management mode with distinctive characteristics and competitive strength, and has shown the advantages of high technology content, high production efficiency, good economic benefits and low energy consumption in production and business activities

in many aspects of quality and efficiency, it has set a new record for domestic shipbuilding enterprises, such as its zero segment docking error of no margin shipbuilding, such as the one-time utilization rate of steel reaching more than 92%, about percentage points ahead of other domestic backbone shipyards

how does Nantong COSCO Shipping Kawasaki achieve lean management? Chen Gong, the Chinese general manager of Nantong COSCO Shipping Kawasaki, told China electronic news that making progress every day is the only way to achieve lean management, and there is no shortcut. When visiting its intelligent manufacturing workshop, I saw "stop-5 second danger prediction" embroidered on the cuffs of every worker. The worker said that every time he raised his hand, he reminded himself to think more carefully about this action. This way of stopping for 5 seconds will gradually become a habit from the beginning of coercion

there is a popular thinking among workers: "the next process is my customer." That is, you should finish your work well, don't leave the trouble to the next process, and at the same time, you should also think about the impact of your work performance on the next work. In order to enhance the awareness of the overall situation, employees often change positions and move to relevant positions in the upstream and downstream for job rotation, so as to achieve the purpose of exercising their ability and transposition thinking. Relying on the perfect system and operation benchmark, the company has achieved the unanimous recognition of customers by implementing the independent management of the whole staff, the whole organization and the whole process without setting up full-time quality inspectors

Nantong COSCO Shipping Kawasaki has many characteristic production site management contents: such as 6S management (sorting, rectification, cleaning, cleaning, quality, specification) and NPs activities (Nantong COSCO Shipping Kawasaki production management system). "6S" management is one of the effective carriers of independent quality management. All production workers are required to eliminate waste and pollution in the operation area at any time. Waste materials are cleared daily, as they are produced, as they are produced, so that there are no hidden dangers in safety and quality. NPs management mainly includes "at a glance management", "ineffective operation management", "personnel multi-functional management", "equipment and logistics improvement management" and other contents, so as to maximize the ability of people, materials and equipment, reduce production costs, and improve construction efficiency and ship quality

it is not only to realize lean management at the production site, but also the lean management of Nantong COSCO Shipping Kawasaki includes all dimensions of the enterprise, from lean design management to lean quality management and lean cost management

in terms of lean design management, Nantong COSCO Shipping Kawasaki will put the lean concept throughout the whole process of basic design, detailed design and production design, realize digital shipbuilding and digital modeling, maximize production accuracy, production efficiency and material utilization, and make the pre outfitting rate reach more than 85%; Implement production-oriented design. Captain Jiang said that this company, Changzhou Tongwang plastic new material Co., Ltd., located at No. 31, zhanghaiqiao, Henggou village committee, takes the production site as the standard, and ensures that each production link can be implemented in the best state through optimized design, Avoid unnecessary rework under bad working conditions

in terms of Lean quality management, Nantong COSCO Shipping Kawasaki is relying on a perfect system and operational benchmarks. By implementing the independent management of the whole staff, the whole organization and the whole process, and without full-time quality inspection personnel who fully comply with Hooke's law, "economically build ships that meet the quality requirements of ship owners" to achieve the high standard quality goal unanimously recognized by customers. Independent management will hand over the quality control to each operator. Through the self-discipline and control of employees, problems can be found, analyzed and solved

in terms of lean cost management, Nantong COSCO Shipping Kawasaki, on the one hand, reduced the steel consumption per ship by optimizing the ship type design, improved the steel utilization rate by optimizing the production design, and reduced the labor cost by reducing the man hours per ship in the design stage; On the other hand, through the establishment of a computer network system covering the whole company and all cost points, it can effectively track and control material procurement, warehousing, working hours, consumption, department expenses, etc. on this basis, it lists the procurement cost control as the top priority of cost management, and correspondingly establishes a procurement cost control mechanism with its own characteristics

"the lean production management mode led by design and the intelligent transformation based on it are very important for the long-term healthy development of enterprises." Chen Gong said. In 2012, Nantong COSCO Shipping Kawasaki established intelligent shipbuilding as the main direction of transformation and upgrading and the main way to achieve a strong shipyard. In July 2017, Nantong COSCO Shipping Kawasaki's "intelligent shipyard construction based on the deep integration of industrialization and industrialization" was recognized by the Ministry of industry and information technology as a pilot demonstration project for the integrated development of manufacturing and interconnection in the shipbuilding industry as an industrial intelligent factory solution

in December 2017, its shipbuilding intelligent workshop was selected as one of the top ten scientific and technological advances in Intelligent Manufacturing in China

when revealing the methodology and experience of Nantong COSCO Shipping Kawasaki in building an intelligent manufacturing factory to China Electronics News, Chen Gong said that in fact, the lean management of manufacturing enterprises and the digitalization and intellectualization of the whole process are in the same line. "If you can't achieve lean operation in all dimensions of the enterprise, you can't talk about intelligence."

the development outline and implementation path of its intelligent manufacturing are hung at the entrance of the Kawasaki intelligent manufacturing workshop of COSCO Shipping in Nantong: "Take digital lean design as the source, integrated information system as the support, lean production and intelligent equipment as the starting point, lean management as the guarantee, take the application of industrial robots and the transformation of automatic production lines as the entry point for the integration of two modernizations and intelligent manufacturing, and promote intelligent manufacturing step by step; build intelligent workshops on the basis of automatic and intelligent production lines and assembly lines." The goal is to form a relatively perfect ship intelligent manufacturing system by 2025, and strive to build an "intelligent shipyard" in the primary stage

from international cooperation to continuous re innovation

in 10 years, Nantong COSCO Shipping Kawasaki has completed 50 years for Japanese shipbuilding enterprises and 30 years for Korean shipbuilding enterprises. By the end of June 2018, more than 190 large ocean going ships of various types had been jointly built and paid, filling many gaps in the history of Chinese shipbuilding, which was 13% lower than the all carbon long fiber variant

"Nantong COSCO Shipping Kawasaki is an enterprise built by China Ocean Shipping Group and Japan Kawasaki Heavy Industry Co., Ltd. in the way of holding 50% shares respectively and with the idea of" three high and one low ", that is, high starting point construction, high-level management and high-tech, low-energy shipbuilding. It is the system and wisdom that each holding 50% shares can operate so successfully." Liangyanfeng, general manager of COSCO Shipping heavy industry, said

Japan's Kawasaki heavy industry, which has a history of 100 years, said that Nantong COSCO Shipping Kawasaki is its most successful overseas investment project. Because of the success of this project, Japan's Kawasaki heavy industry and China Ocean Shipping Group cooperated to build a new joint venture in Dalian

re innovation is the key to sharing and building a supply and demand docking platform for the new material industry for digestion and absorption. In the process of cooperation, Nantong COSCO Shipping Kawasaki did not stop to follow the mature mode of Kawasaki heavy industry, but continued to aim at the world's advanced shipbuilding technology and the development trend of shipbuilding industry. Starting with process optimization, it comprehensively applied advanced technologies such as lean production, information technology and green manufacturing, and creatively established a full process R & D system with cutting-edge technology research capability on the basis of system integration, And quickly form the advantages of general assembly shipbuilding

on the morning of June 30, 2018, the third 20000 TEU Container Ship "COSCO Shipping Capricorn" with completely independent intellectual property rights was anchored at Nantong COSCO Shipping Kawasaki terminal 2. Since January 22, only half a year, three ships of the same type have been delivered successively. Nantong COSCO Shipping Kawasaki's ability and strength in the field of super large ship construction continue to be recognized and constantly set new domestic records

since 2010, with no reference from abroad and no experience at home, Nantong COSCO Shipping Kawasaki has focused on building 13386 TEU super large container ships, which were completed in 2013. In 2011, Maersk shipping company took the lead in ordering 20 18000 TEU Container Ships in Daewoo shipbuilding, South Korea, which became the wind vane of the super large container ship market. Since then, the world's top ten liner companies, including COSCO Shipping, have ordered their own 20000 TEU class super large container ships

the new 20000 TEU super large container ship independently designed and developed by Nantong COSCO Shipping Kawasaki covers the whole process of basic design, detailed design and production design. With a length of 400 meters, a shape width of 58.6 meters, a shape depth of 30.7 meters, and a maximum carrying capacity of 197000 tons, it is currently one of the longest ships in the world. In order to successfully complete the task, Nantong COSCO Shipping Kawasaki concentrated its talents

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