Awesome! One car is produced every minute!
2024-08-10
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【New quality productivity in the workshop】
The "secret" of producing one car in one minute
How long does it take to produce one new energy vehicle?
“It only takes 1 minute.” This is the answer given by BYD Xiaomo Factory.
On July 30, a reporter from the Workers' Daily visited the stamping workshop of the Xiaomo Factory of BYD Co., Ltd. (hereinafter referred to as BYD) located in the Guangdong Shenshan Special Cooperation Zone, and explored the "secret" of producing one car in one minute from the perspective of the stamping process.
Stamping is based on the plastic deformation of metal. It uses molds and stamping equipment to apply pressure to the sheet material to cause plastic deformation or separation of the sheet material. The steel coil sheet passes through the uncoiling and blanking production line and is processed into a flat plate of the required shape for easy subsequent use. In the stamping production line, it goes through five processes including drawing, trimming, punching, shaping, and flanging to obtain parts with a certain shape, size, and performance.
In 2023, BYD Group will sell 3.024 million new energy vehicles, and will continue to be the world's new energy vehicle sales champion. BYD's miracle in the development of the world's automobile industry is inseparable from its manufacturing capabilities. BYD's Xiaomo Factory in the Shenzhen-Shantou Special Cooperation Zone mainly produces mid-to-high-end models such as Yangwang, Denza, and Dynasty series. As a production base for complete vehicle manufacturing, it covers four major process factories for complete vehicles, including stamping factories, welding factories, painting factories, and final assembly factories.
"The factory produces 400,000 vehicles annually, with an average of about 1,280 vehicles produced per day. In the stamping workshop, the parts needed for 60 cars can be stamped out every hour. The maximum number of stampings for the entire line can reach 15 times per minute, which means that the stamping machine can complete 15 complete stamping actions every minute." The manager of the stamping workshop of Xiaomo Factory roughly calculated the "production account" to the reporter. Thanks to the high degree of automation and intelligent manufacturing, a new energy vehicle can be produced here in about 1 minute.
It is reported that as the first of the four major processes in vehicle manufacturing, stamping technology occupies an important position in the automobile body manufacturing process, especially the large covering parts of the automobile body. Most of them have complex shapes, large structural dimensions, some are curved surfaces, and high surface quality requirements. Therefore, the use of stamping processing methods to make these parts is incomparable to other processing methods.
How are the parts that make up the car body, such as the side panels, roof, four doors, front hood, fenders, and trunk panels, formed through stamping technology?
The reporter saw at the scene that after the material personnel transported the plates to be processed from the material warehouse to the designated area of the stamping line, the robotic arm "picked up" the plates and put them on the conveyor belt. After the plates were cleaned and oiled, the crossbar robot took and placed the parts, and transferred the workpieces between the processes and equipment. The plates were stamped and formed after processes such as drawing, trimming, punching, shaping, and flanging. There is a large control console next to the head of each production line in the workshop, and the operator monitors the operation of the equipment and molds in the closed state of the production line in real time.
"Unmanned and automated" is the reporter's most intuitive impression of the stamping workshop.
It is reported that in the past, stamping production relied on the "human sea tactics", but nowadays, with a stamping workshop building of about 60,000 square meters, there are about 5 people directly involved in production on each line in the three production workshops, and the rest are mainly technical personnel such as equipment operation, equipment maintenance, mold maintenance, and quality inspection.
"At present, the degree of automation in the stamping workshop exceeds 80%, and the unloading of materials at the end of the line is also undergoing automation transformation." From traditional labor-intensive production operations to the current 100% fully automatic production in the stamping process, the managers of the stamping workshop have witnessed the continuous advancement of my country's automobile manufacturing technology in the 19 years of their work.
The stamping of sheet metal parts requires a certain amount of press tonnage. The more complex the design of the parts, the greater the force required for stamping, and the larger the tonnage of the press. The Xiaomo factory's high-speed stamping line has a total tonnage of 7,900 tons, the first press has a tonnage of 2,500 tons, and the subsequent presses are 1,800 tons + 1,200 tons * 3. Due to the increase in the tonnage of the presses in the workshop and the maturity of the stamping die technology, the production has achieved the "dual-cavity mode for large covers" - from stamping one part at a time to producing two parts, which not only improves production efficiency, but also greatly saves costs.
"The higher the degree of automation, the higher the skill requirements for practitioners." This is the biggest feeling of the above-mentioned managers.
To this end, BYD is committed to building a multi-level learning organization and establishing multiple online and offline training channels. The training methods include face-to-face teaching, case studies, skills competitions, project discussions, etc., to improve the skills of practitioners.
At the same time, BYD attaches great importance to technological innovation and adheres to the culture of engineers. At present, BYD has more than 100,000 R&D personnel, making it the automaker with the largest number of R&D personnel in the world. The company has applied for more than 48,000 patents and authorized more than 30,000 patents worldwide, with an average of 32 patent applications and 15 patent authorizations per working day.
It is worth mentioning that the reporter saw a busy production scene in the stamping workshop, but there was no noisy sound of machines. The production noise in the workshop did not exceed 80 decibels, which is the lowest level in the industry.
"The low-noise production environment is due to the fact that BYD used sound insulation and noise reduction materials to add external protection when building the production line." A workshop operator pointed to the stamping production line and explained that the external protection made of special materials is like building a soundproof room for the production line, protecting the operators.
It is from such a "quiet" yet busy workshop that cars are shipped to the world, allowing global users to use high-quality Chinese new energy vehicles.
Source: Workers' Daily reporter Liu Youting
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