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从制造到“智造” 探访福田汽车山东多功能汽车厂

2019-2-15 00:15 | 来自:商用车新网

       2018年,福田汽车围绕“聚焦价值 精益运营”发展理念,深耕市场,并迎来了改革大收获。在持续科技创新推动中,福田汽车以1328.67亿再创品牌价值新高,位居商用车行业第一,连续14年领跑商用车行业,彰显迈向世界级汽车的坚定意志。


       成功的背后,是产品力?#32435;?#32423;和生产技术的不断创新,今天编辑?#34892;?#25506;访了福田汽车山东多功能汽车厂,深深地感受到了福田汽车由制造到“智造”的创新历程。

       福田汽车山东多功能汽车厂分为:总装部、涂装部、车身部、员工中心和试车道几大功能区域,今天我们要探访的就是多功能汽车工厂的核心部门——总装部。

       总装一车间分为内饰一、内饰二、底盘一、底盘二、综合线等五条生产线,承担风景G7、风景G9、蒙派克、图雅诺四种车型的混线生产任务。

       进入生产车间后,第一个感觉就是整洁、明亮而且工人的数量很少——这说明生产线的自动化程度非常高,装配过程需要的配件整齐?#34892;?#30340;摆放在流水线两边,地面没有一?#24247;?#27833;液、污泥。

       众所周知,混线生产的一大问题就是:面对多个车型的众多配件、人工备件等作业难免出现失误,甚至导致停线的场景,而?#20234;?#19968;方面也使得工人的劳动量大大增加,为了完成生产任务不得不加班加点追赶进度。

       编辑今天探访的福田多功能汽车厂同时运行着五个产品平台,是国内装配产品最多、工艺最复杂?#32435;?#20135;线之一,那么他们是怎么解决这一问题的呢?

       答案?#20174;?#24037;厂上线的制造执行系?#24120;∕ES系?#24120;ES系统在统一平台上集成了生产调度、产品跟踪、质量控制、?#25910;?#20998;析等管理功能,通过优化制造过程实施完整的闭环生产。该系统上线后,计划准确、零部件配?#22270;?#26102;,工人只需按计划现时进行零部件组装,这样一来不仅不会出现人为失误,工作效率也大大提升,产能自然而然就上来了。

       一个小小条形码,就能?#27809;?#22120;实现物?#29486;?#30830;分拣、信息自动闭合,物料储备信息会与次日生产节奏紧密配合,一粗排、一精排,在同样携带生产信息的物?#29486;?#36816;车的配合下,准确到达生产工位。同时,整个过程有条形码进行信息跟踪,并对数据进行存储、统计、分析、记录和追溯。

       DPS(即摘果式电子标签拣货系统)的运行,是最?#24080;?#29616;智能物流的一个重要方面。DPS系统根据从MES系统接收到的?#23548;?#19979;车?#25215;潁?#21457;出出货指示并使货架上的电子标签亮灯。操作员根据电子标签所显示的数量,及时、准确、轻松地完成以“一台车”为单位的拣货作业,将零部件配载至SPS料车中,由AGV小车自动配送至线旁工位。

      拣选方式改变,取消指示票,减少拣配人员思考步骤,避免拣配出错。开发的DPS电子拣选系?#24120;?#37319;用DPS电子标签完成RDC库的零部件智能拣选。人员按照小灯拣货,实现每拣一个物料熄灭一个小灯,使用AGV将拣选完成的当量份零件运输到生产线的上线点,通过AGV与传送装置的配合实现物?#29486;?#21160;上线。

      在装配机械?#26041;?#19978;,福田多功能汽车厂采用了德国进口?#21335;?#36827;机?#25285;?#20445;证了高水准的装配工艺,高度机械化?#32435;?#20135;大大减少了装配过程中所需要人力,使得更多的工人向技术、管理方面做转型。

      装配完成后在总装车间内还能完成四轮定位等关键工序。

      高度智能化?#32435;?#20135;、管理体系使得福田商用车有着可?#24247;?#36136;量保证,图雅诺、风景等车型?#26029;?#20840;球多个国?#19994;?#24066;场,为福田汽车全球化的战略迈出了坚实的一步。

      一天的探访?#22868;?#24456;短暂,走出总装车间后我深深地感觉到了福田汽车从制造到“智造”的巨大变化,相信随着技术的不断革新,福田汽车在2019年会有更多的突破和更大的收获。
【凡属本站原创文章,如转载请注明“来自:商用车新网”】

发布者: wangx| 来自: |
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