Recently, no one can deny the fact that Aowei Engine has been listed on the market for 8 years and its strong market retention rate has been hailed as a famous machine by the market. The concept of “buying a car to buy liberation cars and selecting machines to select Aowei machines” has penetrated into users. Heart. Aowei heavy trucks have been launched for more than 6 years, and the market has been expanded at an annual rate of 60% sales volume. Up to now, it has exceeded 250,000 units. There is no shortage of users who have exceeded one million kilometers in the rave reviews. Under the influence of the reputation of Aowei Machinery, the production and sales volume of Tinker increased from 150,000 units in 2004 to 250,000 units in 2008, and the sales volume reached 436,000 units in 2010, making it a famous engine brand in China today.

Behind the reputation is the support of quality. Quality and technology have become the two wings where Xichai has achieved a lasting strategic advantage. So how does Xichai create high-end quality? Let us step into Xichai and unlock the “success code”.

From the "build standards" to "take the flow" quality is planned out

“The advanced quality of the CA6DL (Aowei Engine) is planned.” As Xi Qian Qian Hengrong said as a typical introduction to quality experience at the quality promotion conference held by FAW Group Co., Ltd. At the beginning of the development of the CA6DL project, it was clear that the overall goal of achieving "6L" was to target "6L," that is, Large Power, Large Torque, Low Fuel Consumption, Low Emission, and Low. Low Noise and Long Life Time. The target value of planning is "the international level of design, first-class quality, and internationally-leading cost."

"In order to achieve the CA6DL product quality goals, Xixi People established a quality index system including performance, reliability, and cost around the entire process of CA6DL product development, manufacturing, and continuous improvement." Director Heng Rong said that Xixi People originally set up 13 performance indicators of CA6DL products, manufacturing as the main link of quality control, and also set 6 key indicators clearly. Other sub-indicators are decomposed around this main indicator. . CA6DL product quality indicators include B10 life of 800,000 kilometers, 100% of the components meet the requirements of the drawings, 100% of the whole machine is qualified, before the batch is put on the market, the problem is solved 100%. ”

“Let the Xichai people feel gratified that the CA6DL three generations of development passed 47 units of stand-alone verification, the bench test time exceeded 30,000 hours, and the stand-alone machine achieved a maximum of 5000 hours full-load full-load trouble-free operation; after 104 units The entire vehicle road has been verified to have a cumulative journey of more than 5 million kilometers, which has set a domestic record in terms of number of units, time, and mileage...

"Of course, we must ensure that quality is planned. We must establish standards and pay attention to the process," said Xu Boping, director of Xichai's quality assurance department. Xichai paid special attention to quality standards. "In terms of quality management, Xichai has introduced advanced international technologies. The quality management models and methods, combined with the characteristics of the company itself, have formed a unique quality management system.” Xichai has built a quality system with a complete system and a clear hierarchy, and guarantees quality behavior with a standardized quality system.

Since 1996, Xichai has established four levels of quality management system documents according to ISO9001, QS9000, ISO/TS16949, GJB9001A, VDA6.3, VDA6.5 and other quality standards: Quality Manual, Procedures, Management System, Quality recording. Four levels of technical documents have been established: standards, drawings and design documents (including FMEA documents), process documents, and inspection documents to ensure that the quality of the manufacturing process is controlled, process documents cover prototypes, trial production and batch production stages, and products The whole process of manufacturing and all kinds of test processes run well.

"Strictly following the process and not violating the process, is the principle that Xichai has repeatedly emphasized and implemented." In the CA6DL new product development process, Xichai people also adopted the concept of "winning by quality" throughout the entire product life cycle, and Absorb foreign advanced development experience, development process, combined with the characteristics of the factory, established its own three-generation development process, and strictly follow the process of new product development. From the source of design, development, and verification, we firmly control the quality of our products. The new products such as Aowei 7.7L, 8.6L, 11L, 13L, and China III and China IV electronically controlled common-rail diesel engines that were successfully put on the market not only became hot-selling products in the market, but also saw sales growth rank first in the industry, and exports ranked first in the industry. The national automobile industry has added new highlights to FAW.

From the "Top Manager" to the "Iron Manipulator" quality work involves all staff

Good reputation, rising sales, and quality are not only the lifeline of Xichai people, but also the foundation of national brands.

“In Xichai, quality work is the “one-to-one project.”” Xu Baiping said that at present, Xichai’s quality work has already formed a “two-tier three-catch” system that the factory manager personally grasps, directly in charge of leadership, and the functional departments specifically. As a common practice, the “No. 1 Document of the Party, the Party, the Government, and the Government,” issued by the company’s first-hand man, is the outline of the quality work of the year and clearly sets forth the quality policy, work ideas, quality goals, and key tasks for the year.

“There is no doubt that quality is the cornerstone for the survival of Xichai, and it is also the “golden key” for Xichai’s development.” Xu Baiping stated that Xichai has determined two preferred principles for supplier selection, namely, optimizing domestic first-rate suppliers; Suppliers, at the same time, also conduct hierarchical management on qualified suppliers. Each year, 8 kinds of guarantee capabilities and 5 quality indicators are evaluated and graded by the supplier. The classification results are linked to the supply ratio.

In manufacturing quality control, prevention and regulation are the core. The first is to establish a preventive maintenance system for equipment and tooling, and implement statistical process control (SPC) for key processes to provide guarantee for effective control of manufacturing quality. Followed by the establishment of quality warning points, will be visually prone to the quality of hidden dangers and operational attention; third is the use of TPS-related techniques and 5S site management methods, the development of standard operating instructions, regulate the daily operation of employees, improve work efficiency .

In order to ensure the quality, Xichai has established a strict reward and punishment system for quality work. “Iron hand grasping quality” is the consistent behavior of Xichai. Every year at the beginning of the year, Xichai shall convene a quality promotion conference, sign the quality target responsibility letter with all departments of the whole plant, and present more than one million yuan of special funds to reward outstanding quality contributors and quality research projects and departments.

Xichai people will not forget: On February 20, 2004, at the CA6DL Product Quality Promotion Conference, the Quality Assurance Department announced the decision to destroy 11 unqualified parts and components of 10 supplier manufacturers, and took a total of 7 companies. Eleven concession acceptance suppliers, two suppliers with a total of two sub-cleanliness levels, and three suppliers with poor quality of rough parts are subject to corresponding severe penalties.

The actions of the smashed products showed that the Xichai people had genuine confidence in their product quality, realism, and realism. Their world-class quality guaranteed world-class brands with confidence and determination.

Under the influence of the “winning with quality” culture, the awareness of actively discovering problems and actively eliminating hidden dangers has been greatly enhanced. Xichai has emerged many advanced benchmarks of the “woodpecker” type, avoiding many major quality accidents.

In the initial stage of production of CA6DL products, Yang Tingting, an ordinary operator engaged in non-destructive testing of magnetic particle flaw detection, spotted the fillet quenching crankshafts used in the CA6DL engines delivered by Brazil and India and found that five crankshafts had slight diagonal magnetic oxide marks respectively. Clips and connecting rods are used to grind fine cracks in the outer cylindrical neck.

"Aowei quality does not allow any flaws!" Yang Tingting insisted that this batch of crankshafts was "nonconforming." A total of 200 crankshafts! If this batch of crankshafts does not enter the next process in time, the entire production line will have to be stopped, affecting and delaying the delivery date... After the foreign experts heard the news, they were also shocked. They carried the portable testing equipment. "Fly" to re-test, and in a large number of examples to verify that the defects allowed by the material do not affect the material. However, Yang Tingting firmly refused to release. After sampling and re-doing metallography, it was confirmed that there was indeed sulphide inclusions, and the rating was 2.5.

On another occasion, it was learned that Xichai had quality problems when it was assembled at an automobile factory. Through in-depth investigations, the factory strictly penalized 63 persons responsible for final assembly, school bus, and inspection. Among them, one leader was dismissed and one was laid off. The maximum fine was several thousand dollars. With great efforts, not only the whole plant was shocked, but even the car factory was deeply shocked.

From the formation of "quality culture" to "internalization in the heart and externalization in the shape"

Over the years, Xichai has pursued excellence in quality management and has accumulated a unique Xichai quality culture.

It can be said that with the continuous creation of independent new products, the status of the industry's top three continues to be solid, and the development and development of various systems such as design and development, production and manufacturing, procurement management, marketing services and quality management have led to the development of Xichai's characteristics. The quality culture: "Quality is life, life is only once."

The activities closely linked with the quality culture have promoted the deepening of the quality concept. Xichai not only established its own quality museum, but also displayed the successful experience and lessons learned from Xichai's quality life project, forming the first time to do things. Well, for the first time, just put things in the right atmosphere.

Into the CA6DL machine shop (Aowei machine manufacturing workshop), this white-based work site logistics arranged in an orderly, on-site logo clear. Huang Jiansong, the workshop director, said that the workshop put quality-creation “zero-defect” activities as the main measures to improve the physical quality, and through a series of activities such as “seeking quality control stars”, “parameters of zero-risk risks”, and “quality problems bidding”. Employees are rewarded for excellent quality execution and quality improvement.

“Our high-end quality is guaranteed. We rely not only on high-precision equipment, but also on quality standard processes.” Huang Jiansong introduced that each job post in the workshop has a “work standard book” and executes a quality assessment system with a score of 100 points. “99 points is also Failing to pass, this indicates that there are quality problems."

“The product quality is not 100 points or 0 points.” In the CA6DL machining workshop production line group, a few boards are particularly eye-catching. He Liqun, the party branch secretary of the workshop, said: “The team of each production line has a team visual board.” Through these boards The show allows employees to tighten the "Quality String" all the time.

In the CA6DL assembly plant, another “Quality Control Point Setup and Deployment Status” display board clearly reflects the technical requirements, operating equipment, and management methods of each quality control point of the CA6DL and CA6DM assembly lines. Li Hongjian, deputy director of technical quality in the assembly shop, explained that the workshop ensures the quality of the entire assembly process is controlled by the application of error protection technology, electronic coverage of processes, standardized inspection procedures, establishment of quality control points, and quality warning points. At the same time, statistical data analysis is conducted every month in the workshop. On-site precontrol through control charts, once unfavorable trends are discovered, system analysis will be carried out based on XR maps from people, machines, materials, methods, loops, and measurements. Check the causes and formulate countermeasures to ensure that the quality process is stable and controlled... ...

Came to the CA6DL assembly shop operation area, the "production line personnel skills matrix" consisting of three colors of red, yellow, and green immediately came into view, which specifically reflects the skill level of each employee in the production line "yellow color" represents the employee's position In the skill level, “green color” means that employees have multiple skill levels, and a red five-pointed star in front of the name indicates that the employee is “full-line”. Chen Lijun, head of duty, said: The purpose is to motivate employees to master multiple skills, ensure the quality of the tuning, and add a “lock” to the CA6DL assembly quality.

“Quality is life, and life is only once.” This definition of value has been firmly rooted in the heart of all Xichai people. They are casting national brands and high-end power with first-rate quality.

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