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in march 2024, chezhi.com and caresach consulting jointly launched the annual promotion campaign for the selection of figures with outstanding contributions to china's automotive product quality, aiming to demonstrate the innovative practices of managers in the process of redefining and continuously improving product quality in multiple dimensions, and provide a platform for the industry provides new ideas for addressing quality challenges.

in-depth company visits and surveys, and conversations with managers who have made outstanding contributions are important components of this activity. in this interview, zhang yue, senior vice president of career saichi consulting, talked with ai nengming, deputy general manager of the quality department of byd automobile industry co., ltd., about byd's core concepts of quality management under the geometric growth of byd's sales, as well as the management priorities in this process. conducted in-depth communication.

zhang yue (right), senior vice president of caresach consulting, had an in-depth conversation with ai nengming (left), deputy general manager of the quality department of byd automobile industry co., ltd.

during the exchange, ai nengming said that in terms of quality management, byd has clear goals and an attitude of unremitting pursuit of details from the beginning of research and development. all employees are included in the goal management system. everyone has goals and achieves the goal of all employees. participation and the attention of all employees are also the key to byd's brand quality growth.

carefully crafted and deepened the planning and execution of quality management

ai nengming, deputy general manager of the quality department of byd automobile industry co., ltd.

byd, which started with mobile phone batteries, entered the automobile industry in 2003. at first, it gained a foothold with its cost advantage, and then embarked on the road to new energy. it took byd 13 years to go from the first new energy vehicle to the 1 millionth one, and more than 3 years to go from 1 million to 8 million vehicles. this speed of development poses considerable challenges to vehicle manufacturers and suppliers in terms of quality management. the quality and safety of each vehicle are closely related to quality management.

ai nengming said that for more than 20 years, byd has been deeply involved in the manufacturing industry. quality has created byd and is also the foundation of byd. he pointed out that in terms of quality management, clear goals and an attitude of unremitting pursuit of details from the beginning of research and development are the keys to byd's brand quality growth.

targeted management has been established at byd more than ten years ago. it quantifies quality and sets corresponding goals in quality management, led by the president himself. at the same time, this is not simply setting goals, but decomposing the goals to each business department, each factory, and each person at each work station. this means that when the company sets an annual quality goal, the entire company from top to bottom, from business units to factories, from top management to front-line employees, will contribute to achieving this goal.

he gave the example of byd's personnel responsible for cleaning work, who also have to achieve quality goals. the reason behind this is that byd's battery patch products are closely related to cleanliness. breaking down the goals layer by layer, you can see that every byd employee works hard for quality work.

at the same time, he also pointed out that byd has always adhered to the principle of "early participation, early prevention", and quality personnel have been involved in quality management from the beginning of the project, and have been deeply involved in the design and verification work. "a saying often mentioned within the company is: 70%-80% of the quality of a product comes from its design, and 20%-30% comes from manufacturing." ai nengming said. only in this way can the management of design quality be "error-free".

five new questions and ten questions to ensure the balance between innovation and quality

safety is the greatest luxury of electric vehicles (photo courtesy: byd)

byd has always adhered to the concept of "technology is king, innovation is the basis". since entering the new energy vehicle industry, byd has always adhered to independent research and development of core technologies. from three-electric systems to vehicle manufacturing, it has mastered the core of key components and vehicles. technology, and already has many disruptive technologies, such as three-electric technology (battery, motor, electronic control), dm-i super hybrid, e-platform 3.0, ctb battery body integration, yi sifang, yunnan system, etc. the birth of disruptive technologies and products is inseparable from technological breakthroughs and persistence in quality. behind this, the "five new and ten questions" quality management method plays an important role.

ainengming said that the "five new and ten questions" ensure the stable batch production of innovative products. through the "five new" (new products, new technologies, new processes, new suppliers, and new origins), risky products are identified, and through the "ten questions" "(whether the qualifications and experience of the project team can guarantee the quality of product development, etc.) quickly carry out risk refinement, identify and improve specific problems, and form a consensus throughout the company and promote its use to ensure steady improvement in quality.

he pointed out that technological innovation means the existence of many variables, and variables are the enemy of quality management. for the first-release technology, there is no experience to follow in quality management. the quality department establishes standards from scratch. it needs to pay more attention to testing and verification and strictly control the development process.

ai nengming takes the emergency floating function as an example: emergency vehicle floating is an industry-first technology. how to ensure that the vehicle floats and does not leak has once become the biggest obstacle to mass production of models. various attempts to comply failed, forcing everyone to rethink, and the final decision was to trace the actual floating results back to the parts and components for control.

in the end, sealing requirements were put forward for nearly 200 products based on leakage points, and nearly 4,000 control requirements were put forward for the four major processes. at the same time, they were supplemented by 100% sealing inspection of parts, and 100% leak detection of vehicles in the trial production and mass production introduction stages. measure the control effect, and promptly formulate and optimize control requirements when new leakage points are discovered. after mass production, the effect is verified again through baidouyi. this work lasts for more than half a year, and relies on front-end process control to 100% guarantee the results of the entire vehicle.

global vision to achieve "unification" of quality management

leading quality relies on leading technology, equipment, quality system, and the accumulation and precipitation of nearly 20 years of ingenious manufacturing (photo courtesy: byd)

quality is the lifeline of an enterprise. if the quality is not good and the customer experience is poor, the reputation will decline, which will affect repurchase and recommendation, thus affecting sales. in terms of quality construction, byd internally implements the iqs quality management system, which aims to reduce product failures and improve product quality. the larger the number after iqs, the greater the average number of failures per unit time.

ai nengming pointed out that in 2008, the company required to continuously reduce iqs through quality management, with the goal of reducing it to less than 10 by 2012. after four years of hard work led by ai nengming, by the end of 2012, all newly produced models had reached the iqs10 level.

after reaching iqs10, ai nengming and his team continued to challenge higher iqs goals, and finally reached iqs1.0 ten years later.

in 2024, the company has set higher quality goals. this also places higher demands on the quality team, especially given byd's rapidly growing sales and continued expansion of its overseas footprint.

"our product standards are the most stringent in the industry. blade batteries pioneered the "everest" of industry safety testing - acupuncture testing, which redefined the safety standards of electric vehicle batteries." ai nengming said. there are many similar standards at byd, and products must meet stringent standards before mass production. in all byd bases and all production lines, one sequence and one inspection are implemented, that is, one process and one inspection. "we have applied a large number of intelligent manufacturing and automated production equipment for inspection here, which has greatly improved the accuracy and efficiency of production. reduces manual error.”

these strict tests and quality controls provide a strong guarantee for byd to maintain product consistency globally, allowing products to meet the needs of the entire vehicle life cycle.

at the same time, he also mentioned that byd is customer-centric and has established a global market research team to understand customer needs in different markets and conduct comprehensive adaptability tests in target markets based on the driving habits of local customers. through these measures, we ensure that the vehicles sold in the local market not only meet the different terrain environments of this market, but also meet the usage requirements of local customers. so far, byd has received extensive positive feedback from domestic and overseas markets, which has also become the motivation for the quality team to persist.

in 2023, byd will sell 3.02 million new energy vehicles, ranking first in global new energy vehicle sales. in the first half of this year, byd auto sold a total of 1.613 million new energy vehicles, ranking first in domestic car sales and ranking first in global new energy vehicle sales. on this basis, ai nengming also mentioned that byd will also launch a series of system solutions such as smart cockpit and smart driving this year to fully develop the second half of automobile intelligence.

"creating things first creates people" is the core, "customer satisfaction" is the driving force, "all employees' quality" is the goal, and we insist on practicing "prevention first, strict compliance with rules, closed-loop management", which is byd's "quality culture 123". in ai nengming's view, it is the practice of such quality culture that allows byd to always stay ahead in the fierce market competition.