Recently, Mr. Harald Mueller, general manager of Volkswagen Auto (China) Co., Ltd., visited the heavy-duty engine production base in Xichai and participated in the test drive of the Aowei J6 heavy-duty truck. He personally experienced the good performance of the Aowei 11-liter engine. He believes that Xichai Aowei engines can compete with world-class products.
The Xichai engine can be appreciated because of the concept of quality as life, the specific actions of winning with quality, and the goal of leading and internationally renowned high-end power brand suppliers in China.
Scratching detail management and strict quality control
In Xichai, quality work is the “one-stop projectâ€; quality control is endless, and it is also an action for all employees to participate. At present, Xichai’s quality control work has formed a “two-level three-catch†system that the factory manager personally seizes, directly in charge of the leadership, and the functional department specifically grasps; it has formed the quality from the source of design, and the quality has been captured from the outsourcing of external components. , quality from the production and manufacturing pattern.
Xichai moves quality control to new product development, its quality management system and certification process, covering the entire process from development, testing, production, promotion to after-sale tracking and investigation. Through a series of measures, the quality problems exposed at various stages were quickly solved, and the overall improvement of the quality system was promoted. Therefore, Xichai's total line-to-line zero-kilometer failure rate ranks the lowest in the industry.
In the parts of the Xichai machine, outsourcing parts and accessories accounted for more than 99%. The quality of outsourced external parts directly affects the quality of the xicai machine. Xichai has identified two preferred principles for supplier selection, namely, optimizing domestic first-rate suppliers, optimizing international suppliers, and seeking cooperation between the two parties “concentricity, alliance, and win-winâ€. In Xichai's procurement system, strict implementation of "four synchronizations" means simultaneous development of new products, simultaneous technological transformation, simultaneous improvement of quality, and simultaneous improvement of management. Signed a letter of commitment with the relevant supplier and asked the supplier to insist on the improvement of the quality: "The reasons are not checked, the measures are not clear, the measures are not clear, the correction is not carried out, the effect is not achieved, the effect is not achieved and the treatment is not serious. Do not let go." Xichai also implements performance evaluation among suppliers, evaluates the four elements of supplier's quality, price, delivery and service on a monthly basis, makes evaluation conclusions every six months, and classifies similar suppliers into three levels. Implement policies such as supply share and capital withdrawal.
In the quality control of production and manufacturing, in accordance with the principle of leading manufacturing level, advanced technology and advanced quality control, Xichai's machining line integrates agile, high-efficiency, automation, and information technology, and its manufacturing level is in the leading position in the world. . In particular, the Aowei 11-liter engine production line at Aowei heavy-duty diesel engine base employs a number of online error prevention technologies such as laser error prevention, photo error prevention, and quality information collection central processing system, and uses Marposs systems for critical size inspection, manual sampling, etc. The "three channels" are of good quality and can detect and solve quality problems in advance.
Fine engineering manufacturing quality machine
At the beginning of this year, Xichai fully launched the "fine engineering." Xichai has defined five aspects of “fine engineering†around design, procurement, self-manufacturing, assembly and distribution, focusing on five aspects: design quality improvement, procurement quality improvement, self-made parts quality improvement, assembly quality improvement, and distribution quality improvement. To solve problems plaguing production sites, steadily improve process quality control, and continuously improve product consistency.
In order to ensure the effective advancement of the five aspects of work, Xichai has established a leading group and set up five working groups to formulate relevant measures around the objectives. 46 refinement projects were established.
Xichai compiles a project implementation table for each sub-item, implements and tracks it on a monthly basis, and forms a monthly refinement project report at the end of the month, summarizing implementation status, highlights, and key points. At the same time, Xichai actively investigates the compliance rate of parts and components. So far, a total of 367 kinds of 6DL2 series parts have been investigated, 100% meet 328 types, with a compliance rate of over 90%; and 359 types of 6DM2 series parts have been investigated, and the compliance rate has reached 100%.
Xichai also implements SPC, error prevention techniques and standard operations to stabilize and improve the process quality. At present, the quality of the three-leakage, product appearance and other aspects of the diesel engine assembly process has been improved to achieve satisfactory results. The promotion of refinement projects laid a solid foundation for Xichai’s goal of achieving quality leadership.
Reliability engineering achieves high quality
Reliable product quality is the basis for Xichai to build China's leading and internationally renowned high-end power brand. Since October 2012 when Xichai has implemented a comprehensive reliability strategy project, it has always put the improvement of product reliability as a top priority for corporate quality work.
In 2013, when the reliability work achieved periodic progress, in early 2014, the factory's party committee established a deepening reliability strategy project as the main line, through the standardization of the improvement process, pay close attention to physical improvement, detailed claims management, and further improve the quality improvement. Timeliness and effectiveness of the quality of work program to achieve J6 thousand car claims frequency to ensure that the pressure drop of 10%, the challenge pressure drop of 30%.
Xichai first standardized the quality improvement process. Through the establishment of a quality improvement test base, the verification of quality improvement effects has been quick and effective; the “National Fourth Product Market Emergency Service Plan†has been specifically formulated, a three-tier service system has been established, and a six-country four-product emergency service team has been established. Raise the major problems in the country's fourth product market and quickly handle the response capability.
Xichai devoted itself to quality improvement. Fully grasp the quality improvement projects of 13 liberation companies. At present, most of the projects have already reached the target of decline or have shown a significant downward trend. For some typical incurable diseases, Xichai has established 12 factory-level quality research projects to solve problems; Promote the physical quality improvement of L/MTOP30 procurement parts, organize 44 suppliers to determine 53 quality improvement projects, and implement the link between supply quality and supply ratio, and strengthen the management of suppliers. At present statistics, Xichai L The 12MIS 1000-car claim frequency for the TOP30 purchases of the M/M machine dropped by 31.6% compared with the same period of the previous year.
Xichai also strengthened internal claims management. The claims management process has been streamlined, and by conducting on-the-spot guidance and confirmation of major issues and filing a large amount of claims, special service personnel have been assigned to provide technical support and guide service stations. According to statistics, since the implementation of the special services in the Jilin-Yilong region, major fault claims have fallen sharply year-on-year, and this year has been promoted in a wider range; as of July, the frequency of regional claims for implementing special services has dropped by 43.6% year-on-year, which is much higher than the decline. Average service station nationwide.
In 2014, Xichai not only realized significant reduction in the Three Guarantees cost, but also saved a huge amount of factory costs. Moreover, the frequency of claims for thousands of vehicles for J6 road vehicles and J6 construction vehicles has been reduced by 10% and 25%.
Superior performance and reliable quality have made Xicca unique in the automotive market. The concept of “buying a car to buy a liberation car and selecting a machine to select a Xichai machine†has penetrated into the hearts of users. According to the customer satisfaction survey released by Coroth (Shanghai) Consulting Co., Ltd. this year, the indicators of reliability and number of first-time failures of the Xichai parts are better than those of competing products, and customer satisfaction is similar to that of domestic companies. The same kind of products also occupy the leading level. The customer's satisfaction with Xichai's products, willingness to purchase, and willingness to buy will increase substantially, and it will have significant advantages over engines with the same power range.
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