Analyze the gap between the production process of domestic and foreign valves
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The domestic process behind the valve welding process, some also use the old welding method, the welder technology level is low, the welding material is also an ordinary material, can not reach the special valve design requirements. A lot of companies are busy with production and sales all day, and they rarely make improvements in the process.
In the application of new technology for die forgings, the KSB company produces valves made of high-temperature resistant alloy steels F91 and F22. The high-pressure valves are mainly made of forged parts, which ensures the reliability and economy of the products. For large batches of 600Lb or less gate valves with forging and welding, the valve did not cause many defects such as porosity, looseness due to casting, and greatly reduced the waste of free-forging materials, greatly improving economic efficiency.
In the domestic industry, most of the valve blanks are made of cast parts, and die forging is rarely used. Valves with a high pressure below 600 Lb can be said to be extremely rare. In order to reduce costs, many enterprises in this area mostly use cast steel parts, low-pressure cast iron parts, low material cost, and simple processing technology.
The gap between quality management and equipment France's Bernard electric device company sales in 2005 was 300 million yuan, exports accounted for 70% of sales, the establishment of a global sales network, China's metallurgy, paper, water treatment and oil and gas pipelines The valve used a large number of the company's electrical products. In the field of nuclear power, their supply ranks second in the world, and more than 70 nuclear power plants in France use their products. Their management is in place. The company's parts processing records are transferred along with the parts. The production site is neat and tidy. The two assembly lines are working in an orderly manner. Their screw processing adopts rolling method, high efficiency, and high surface finish of parts. The processed parts are cleaned in a timely manner, and the station equipment is properly applied. For example, a plastic bag is placed on each shaft, which is very simple but practical. It avoids scratches and scratches between parts. The coating method of the parts is similar to that of the domestic ones, but because the blank itself is smooth and the quality of the paint is excellent, the product after the painting has a very good appearance and quality.
In contrast, there are still many defects in quality management in China. First of all, the process is more or less neglected. Many companies clearly have a quality assurance system, but they can't use it in practical work. Quality management is performed on its own and is arbitrary. Secondly, it is a sloppy thing in the assembly process. It is no wonder that some valves have appeared running, running, dripping or leaking as soon as they are installed.
Another example is the backwardness of many domestic enterprises' production equipment, which has remained at the level of the 70s to 80s of last century. Some equipment has already passed the service life and is still running at full capacity. How can the quality of product processing be guaranteed? Some of them are limited to funds and they are gradually adding CNC and machining centers. However, the number of enterprises that form CNC machining has not been large in the industry so far, accounting for only about 20%.
Disparity in process management The layout of the equipment of the French company Weyland is carried out according to the product process route in order to achieve the shortest processing route so that the operator can complete the workpiece processing within the minimum range of motion. They have adopted a large number of machining centers and even five-axis linkage flexible machining centers, CNC turning and milling machine tools and CNC machine tools, connecting computer-aided manufacturing into a single line. Products are clamped and programmed once on the equipment. The programming work can even be remotely operated in the office, which simplifies the machining process. As long as the engineers and technicians program the program and choose the right tool, the processing requirements of the product can be guaranteed and the product can be of high quality and high efficiency.
Similarly, the production process of Italy's New Guinean company is characterized by: After receiving orders, the design and development center will be transformed to provide technical documents such as product design drawings, outsourced outsourcing details, and mechanical processing programs, which will be transmitted to related departments through the internal network. The production department organizes production according to technical requirements and sales orders. After the blanks are brought into the factory, the warehouse personnel will send the blanks and other parts to various processing and assembly sites according to the production plan. They are not all self-produced, and many are also purchases. However, almost all of their product components are completed on numerical control equipment with high precision and high processing efficiency. Employees can read the parts processing drawings and parts processing programs on the console of the CNC machining equipment. He only needs to press the workpieces to the CNC equipment according to the processing technology requirements, start the processing program, and can automatically complete the car, drilling, milling,é•— and other processing processes.
However, many domestic valve companies are not professional, small and complete, products are mixed, processing valves are chaotic, the layout of workshop processing equipment is unreasonable, and parts and components are not stacked. At present, the domestic piece-rate working hour system is commonly used, but there are also similar problems. The working hours are unreasonable. Most of them also use the original manual record settlement. It is precisely due to the limitations of some enterprise process management levels, resulting in low product technology levels, lagging processing technology, and serious waste of raw materials.
In addition, the layout of domestic machinery processing equipment is mostly arranged according to the type of equipment, such as the arrangement of machining centers, horizontal in a row, vertical in a row, CNC machine tools in a row, this arrangement only consider To the site neat, without considering the ease of operation, labor efficiency is low, the cart before the horse.
The gap in technological innovation capacity is insufficient for technological innovation, which is a stumbling block to the development of our valve industry. At present, many domestic valve companies have rarely reinvented after introducing advanced technology. The result is that it is difficult for valve companies to export their products to Western markets.
In fact, regarding the technical level, the design of conventional valves and the application of materials, we do not have much difference compared with well-known foreign companies. There is no insurmountable gap in the manufacturing process. What is the difference? In fact, it is worse than the word. There is such a product, originally a patent valve of a company in Germany. There are several different companies producing at the same time. One is a foreign company, one is a Taiwan-funded company, and the other is a domestic company. The same product map, the valve produced is actually the same. The first two companies are better than domestic companies in terms of internal quality and appearance. It is puzzling that these companies are producing such products in China, and the castings are made from domestic factories, but the results are quite different. In a sense, there is a big gap between our business philosophy, our pursuit goals and foreign-funded enterprises, and there are indeed certain problems in the processing of rough products. We must also think deeply.
The practice of foreign companies in plant construction is also different from Chinese companies. China’s enterprises first built infrastructure, expanded production plants and added production equipment. The factory buildings were expanded and expanded, pursued large-scale, modern style, and only wanted to expand the scale of production, ignoring the R&D and investment in new products, and the product’s stamina was seriously insufficient. Most of the production products are imitations, and only ordinary low-grade products are produced, and too much effort is put into market operations, thus lacking core competitiveness. Some domestic companies engaged in research and development, the more is to refer to the design of other manufacturers, thereby ignoring the importance of the original experimental data, so that the product developed only has the appearance and no real soul.
Forming a joint force to accelerate the development of the valve industry is a major competitive advantage of China's valve industry. At the same time, China's continued growth in market space is also a prerequisite for China's valve industry to maintain its advantages. However, this is only the external advantages of the enterprise and it is not the core competitiveness of the enterprise.
In order to solve the problems existing in China's valve industry, the state has also formulated some policies to encourage the development of the valve industry, promote domestic enterprises to master complete R&D and manufacturing technologies, and at the same time the rapid development of domestic economic construction and the construction of many large-scale projects are also domestic The valve industry has created enough market space. Under this situation, China's valve industry should seize the opportunity to catch up.
Innovation is the only way for the development of the industry. If a nation does not innovate, there will be no soul. A company does not have its own core technology, so in the international industrialization division, it can only serve as an international worker. At the same time, we must pay attention to the improvement of management. Establish a corporate culture, work hard on human resource management and computer-aided manufacturing, and increase labor productivity to achieve good economic results.
Obviously, there are gaps are not terrible, as long as we adjust the development of ideas, enhance development confidence, strengthen corporate management, promote technological progress, attach importance to technological innovation and core technology research and development, improve the company's core competitiveness. In the near future, China's valve backbone enterprises will surely be able to catch up with and surpass their foreign counterparts, contribute to the nationalization of major national technical equipment, occupy a certain share in the world valve market competition, and become a strong country in the world of valve manufacturing.
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