A few days ago, in a large digital workshop of Wuzhong Instrument Co., Ltd., the operators were working carefully. Every day, tens of thousands of parts orders are sent from dozens of sales outlets across the country such as Guangzhou and Hainan, and nearly 200 pieces of equipment in the workshop are processed and produced.
Because of the harsh working conditions, the valve must have high wear resistance, erosion resistance, high sealing and other properties, only after the grinding of machines and technology, the ball core can reach the accurate roundness and finish.
"We grind nearly 12,000 cores every year, and the error of each core is guaranteed to be within 5 microns, which is equivalent to one-tenth of a hair's hair, and this delicate core grinding process is the result of more than 50 years of accumulation." Gu Jie, the head of the ball core processing island of the company's ball valve division, said.
Wuzhong Instrument is engaged in the production of control valves, and its products are used in petroleum, chemical, nuclear power and other fields. The ball core is the central part of the control valve, which plays the role of regulating the flow of the valve medium, the quality of the ball core determines the quality of the valve, and the processing and production of the ball core is the central skill of the control valve.
In 2010, the company adjusted the production arrangement structure from scratch, listed ball core processing as an important department, and merged the scattered four ball core processing points into a ball core processing island. So far, the curtain has been opened to overcome the key skills of ball core processing.
The newly established ball core processing island, the equipment is outdated, the quality of the personnel is low, and the previous production and processing technology is still used. But soon they clarified their thinking, knew the key problems and antagonisms that limited the efficiency and quality of core processing, and formulated a "three-step" operation plan to improve the efficiency and quality of core processing. The first step is to adjust the position of the equipment according to the spherical core processing process, and the equipment of the same model is installed together according to the idea of one person and multiple machines, so as to realize the operation of more than 3 equipment by one person, which saves the turnover time of spherical core processing, reduces the number of personnel in the transition, and greatly improves the operation efficiency.
"The second step is to upgrade and transform all processing equipment, and then the third step is to arrange team members to tackle the problems of ball core processing skills." Gu Jie said that at that time, the team members pushed the "craftsman energy", used their spare time to move the equipment, and completed the moving device of nearly 30 pieces of equipment in just 3 months, which did not affect the normal production, and after the equipment was combined from scratch, more than 30 processing processes were reduced, a lot of manpower and material resources were saved, and the production efficiency of the equipment was increased by nearly 10 times.
In the second half of 2010, they began to implement the second and third steps of the operation plan, for 30 sets of equipment, one by one research and development of technical transformation plan, production of transformation drawings, research and development of tooling fixtures. After more than a year of hard work, all the technical transformation operations have been completed, and the way that a piece of equipment can only process one ball core at a time has been changed in the past, and at present, a machine can process 10-20 ball cores together, and the ball core processing efficiency has increased by 20 times. Together, they explored and summarized more than 50 new processing technologies, solved the problem of improving the processing accuracy of the ball core, and the ball core skill index reached the level of no leakage, supporting the processing of ball cores for many world-renowned enterprises.
Because the ball core processing has achieved new development, the company's production capacity has been greatly released, the product skills have reached the same level in the world, and the quality of individual products is better than that of imports, which has won the praise of users and laid the cornerstone for the development of the enterprise market. At present, the annual production and processing capacity of the ball core processing island reaches 100,000, which can create economic benefits of about 300 million yuan, and the annual output value of the per capita invention of the team ranks first in the company, and is also among the best in the domestic industry.
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