Endeavour on the Road of Digital Transformation | Sun Jianxun, General Manager of Lianqiang Roll


Time:

2023/12/12

At present, the steel industry is setting off a wave of digital revolution. As an important part of the steel industry, the roll manufacturing industry is also facing the same opportunities and challenges, how to complete the baptism and transformation in this massive wave? Sun Jianxun, general manager of Chaoyang Lianqiang Roll Co., Ltd. (hereinafter referred to as Lianqiang Roll), handed over his answer.

At present, the steel industry is setting off a wave of digital revolution. As an important part of the steel industry, the roll manufacturing industry is also facing the same opportunities and challenges, how to complete the baptism and transformation in this massive wave? Sun Jianxun, general manager of Chaoyang Lianqiang Roll Co., Ltd. (hereinafter referred to as Lianqiang Roll), handed over his answer.

The trend is imminent

When it comes to the significance of the digital transformation of the roll manufacturing industry, Sun Jianxun, general manager of Chaoyang Lianqiang Roll Co., Ltd. (hereinafter referred to as Lianqiang Roll), has a deeper understanding! He said that with the continuous development of science and technology and the intensification of global market competition, the digital transformation of the manufacturing industry has become an inevitable trend to improve the competitiveness of enterprises and adapt to market needs. Because digital transformation can help manufacturing companies realize production process automation, remote monitoring, collaborative development and other functions, it is of great benefit to improve production efficiency, reduce production costs, optimize product quality, and promote the transformation and upgrading of the manufacturing industry to high-end, intelligent and refined.

When it comes to roll manufacturing enterprises why need, and how to achieve digital transformation?Promote high-quality development of manufacturing industry and consolidate the foundation of real economyThe press conference disclosed that in the past ten years, the added value of my country's manufacturing industry has increased from 16.98 trillion yuan in 2012 to 31.4 trillion yuan in 2021, and its global share has increased from 22.5 percent to nearly 30 percent.

Deepening the digitalization of the manufacturing industry is the top priority of "accelerating the green transformation of digitalization and boosting quality and efficiency. It promotes the in-depth application of 5G, industrial Internet, intelligent manufacturing and other technologies around key links such as research and development design, planning and scheduling, production operations, warehousing and distribution, quality control, marketing management, supply chain management, etc., to achieve agile demand perception, agile supply, lean production, fine management. It is the general trend to promote the data exchange, information exchange, production coordination and resource sharing between the upstream and downstream of the industrial chain..

Arming theory focuses on practice

As a traditional manufacturing industry, the roll industry is facing a reshuffle in the digital transformation! Facing this new opportunity and challenge, Sun Jianxun pointed out with confidence: The traditional backward roll production mode of semi-manual and semi-mechanical methods can no longer keep up with the pace of the times; digital transformation will be a reality that roll manufacturers must face. However, the digital transformation of roll manufacturing enterprises is a huge and complex work, which not only requires sufficient funds and a lot of time, but also requires a lot of demonstration and resource integration from the aspects of production, equipment, management, personnel and so on.

Based on the above understanding and ideas, General Manager Sun Jianxun creatively proposed to "build a high-end green digital new manufacturing benchmark for customers, the future, and the world!" As the development vision of Lianqiang roll; It will realize equipment mechanization, equipment automation, manufacturing informatization and operation digitalization as the upgrading policy of Lianqiang roll to realize digital transformation in four steps. Committed to the research and development of core technology, upgrading the traditional production equipment as the company's strategic goal in the next three years.

With the theoretical basis of the guiding ideology and clear objectives, it is all the more necessary to act in a down-to-earth manner. Under the leadership of Sun Jianxun, Lianqiang Roll has carried out the work of promoting the digital construction of enterprise production. They start digital upgrading and transformation from each production node, connecting points into lines and lines into surfaces, and finally realize functions from order management, customer management to product process management, inspection data query, pre-furnace composition adjustment, production process data query, raw material library management, tooling library management, personnel information management, automatic heat treatment control, automatic processing procedure molding, etc., thus improving production efficiency and quality, the construction of a new type of enterprise has been realized. Finally, a three-tier information management mode is formed: the upper level is ERP, which is responsible for information communication and reporting of the management level; The middle level is MES, which is responsible for production information management. The bottom layer is PLC, which is responsible for equipment operation and management, a new situation of production that keeps pace with the times.

The picture shows the roll digital factory exhibition center located in the hall on the first floor of the office building of Chaoyang Lianqiang Roll Co., Ltd.

Down-to-earth initial results

As a production process with high technical content and very intensive manual operation in the manufacturing process of roll products, the digital upgrading of casting is the first and difficult part of the whole digital construction project. Due to the above conditions, the transformation work is difficult to achieve in one step, need to go through mechanization, automation, and finally can be digital. Therefore, under the decision of general manager sun jianxun, lianqiang roll digital construction team first decomposed the whole casting process, and digitally transformed the four modules of modeling, batching, smelting and pouring separately. after the digitalization of sub-modules gradually matures, the integration work will be carried out, and finally a complete set of digital casting production line will be formed.

In terms of digitization of heat treatment process, Lianqiang roll has already planned and prepared the digital factory project at the beginning of heat treatment equipment purchase. Therefore, at this stage, Lianqiang roll heat treatment equipment has been equipped with digital information ports. By connecting the heat treatment furnace to MES system, remote control of heat treatment process can be realized, and the furnace installation plan and heating process of each heat treatment equipment can be made at the remote end, the operation status of heat treatment equipment can be monitored in real time and instructions can be sent.

In the aspect of digitalization of machining process, through the intervention of MES system, the control of the whole process of workshop production is realized, so as to know the progress of each order and the process of product circulation in real time. Through the digital production management system, the processing batches can be reasonably allocated, the whole process tracking of batch rolls can be realized, and the production progress can be displayed in real time.

The picture shows the function of MES system handheld terminal in the digital factory of Chaoyang Lianqiang Roll Co., Ltd.

The picture shows the product processing information page.

In terms of warehouse management, through the use of digital management system, intelligent management of goods is realized. Product information is stored in the database through bar codes and other forms, and goods location is delivered in fixed-point quantity through intelligent management. Therefore, many disadvantages of traditional warehouse management can be effectively avoided, such as low manual recording efficiency, high error rate, waste of human resources, high management and maintenance cost, etc. In order to improve the timeliness and accuracy of material sending and receiving, at the same time, the data can be fed back to the managers in real time, so that the managers can fully grasp the storage situation and make timely, accurate and scientific decisions.

For the equipment manufacturing industry, quality inspection is a very important and rigorous process. Advanced inspection tools and scientific inspection methods can not only improve the quality and accuracy of products, but also analyze which link in the production process according to the inspection big data. Problems, avoid in advance, thereby improving production efficiency. Detection is divided into component detection, temperature detection, time detection, hardness detection, size detection, flaw detection. Upgrade the existing detection equipment to digital equipment, access to the network, and transmit the detection data to the database in real time to facilitate statistical query and improve the efficiency of technical analysis.

 

The figure is a quality detection interactive terminal.

Through the gradual landing of the above digital transformation project, Lianqiang Roll will realize the whole process production control management, the collection, storage and analysis of the whole process quality data, and the visual interconnection of customer needs, forming a complete set of production, management and service data links. At that time, Lianqiang Roll will realize "creating a high-end green digital new manufacturing benchmark for customers, the future and the world!" The company's strategic development goals lead the development direction of the industry.