CAPP's comprehensive application in Chongqing Weichai accelerates the development of digital collaborative manufacturing

“Informatization system is the core of supporting business data processing. It requires system providers and application parties to cooperate in depth to ensure the stable and stable operation of the system. Thanks to Beijing Axter Technology Co., Ltd. for providing Chongqing Weichai Process Information System since its construction. Professional technical support and post-service."

——Chongqing Weichai Enterprise Management Office Zhou Zhijun (Deputy Director)

background

Chongqing Weichai is a wholly-owned subsidiary of Weichai Power Co., Ltd., and the information construction is based on the principle of “coordinated planning and step-by-step implementation”. Under the leadership of the group, ERP, PDM, MES and other systems are gradually implemented and applied. The land supports the production management business of the enterprise. As a company specializing in the design and production of internal combustion engines, Chongqing Weichai faces pressures on product innovation, production organization management optimization, and technology upgrades. At the same time, it also involves the exchange of information and data with Weichai Power Headquarters and the needs of the Group's comprehensive collaborative management.

As one of the key information projects of Chongqing Weichai, CAPP aims to provide a complete data source for ERP, and establish a networked process information design and collaborative management platform to meet Chongqing Weichai's efficiency and development of process design. The overall information construction and the need to achieve digital manufacturing.

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Problems facing informationization

With the increasing product innovation and project-based orders of Chongqing Weichai, the demand for process design and production management is increasing, and the following problems have arisen.

Process design means - lack of professional process design tools, there is no obvious room for improvement in process preparation efficiency.

The process design is not completed by a professional computer-aided process design system (CAPP). The main energy of the process designer is used for manual filling of process code cards, statistical process reports, etc.

The tools used by the craftsmen to prepare the process are not uniform. There are AutoCAD and Word, and the preparation of the process is time-consuming and labor-intensive and error-prone;

The process document is signed and signed by the manual after printing. The process cycle is long and no paperless office is realized.

There is a need to further improve the effective management of electronic documents (process documents). Fill in the content, document format, and version need to be further standardized and unified.

Process management requirements

Although the company's process system and documents are complete, the operation and management methods are based on the paper medium operation mode, and the gap between the requirements for establishing digitalization is large;

Although the company's process design implements computer processing, it is only a partial application, and only a “squeaky pen” is realized. There is still a certain distance for the process to provide structured process data to the manufacturing system.

The lack of a database of process resources makes it difficult to share resources easily.

Collaborative management

At present, the BOM data is transmitted from the PDM system to the ERP system. However, due to the lack of a professional CAPP system, the process data required for the ERP of the product manufacturing BOM, process route, etc. can only be manually improved in the PDM system. The integration between various information systems (PDM, CAPP, ERP) needs to be further improved, and the goal of “single out, global sharing” should be achieved.

solution

Chongqing Weichai and Extech have established a CAPP project team, which is carried out in phases according to the principle of “overall planning and step-by-step implementation”. Successfully implement a module, apply one module, benefit one module, carry out evaluation and implementation of subsequent modules on this basis, establish Weichai complete process documentation service and perfect process document management system to ensure Chongqing Weichai information investment It can be used to bring efficient returns to the company. After in-depth research, the objectives are as follows:

Build a company's process design and management collaborative work platform to improve process design efficiency;

Standardize the company's process data to provide the necessary data sources for ERP;

Establish a process management system that complies with the TS16949 management specification;

Integrate with PDM and ERP to achieve high data sharing.

CAPP project implementation process

Unified base library: Establish database templates for the company's process basic resource data (including tools, tools, gauges, fixtures, equipment, process parameters, etc.) to integrate process infrastructure resources. Provide process-based data sharing and call services for process personnel when preparing process cards.

XTCAPP Process Card Compilation (Standard Module): The product structure tree is used as the organization, adopting the “what you see” method, supporting the graphic and text mixing, supporting the automatic summary generation of process reports, and greatly improving the design efficiency of the process personnel.

Process BOM management: The design BOM is adjusted to the process BOM, which lays the data foundation for the subsequent process routing and process division.

TS16949 professional support module: Provides the preparation of process flow chart, control plan, FMEA, work instruction book and other documents according to the company's PPAP file package template format. Provides management of the FMEA library and automatic calculation of the FMEA.

Process route and division of labor: support multiple multi-level process routes for the same component; realize space technology route and process route for component parts to be conveniently and quickly prepared; batch process division of parts according to space process route.

Process document review: Implementing the review, annotation, and signing of process documents in CAPP to achieve automated office.

Process file version management: On the basis of process file status management, process file change, version management, record change notice, support review of change orders and process files, and release of change information, which can be browsed at any time during this process. Go to the corresponding card and perform batch version control on multiple processes at the same time.

Collaborative management: realize the collaborative application of data and information between PDM, CAPP and ERP systems, and achieve the goal of “single out, global sharing”.

CAPP project running status

The value that CAPP brings to Chongqing Weichai

For Chongqing Weichai, the successful operation of the CAPP project has greatly shortened the process preparation cycle and accelerated the production process. It has liberated the inefficient work of the technicians to review historical data, data changes, approvals, information transmission errors, etc., and focus on new product development and customization projects. In terms of management, enterprise managers are freed from a large number of file constraints, dredging the production data bottleneck of multi-system operation, realizing process data sharing, and ensuring the integrity and security of process data. The in-depth cooperation with Extech is not only a result of the construction of the CAPP system, but also a new understanding of the company's information implementation, operation and management methods. In the face of the goal of “digital manufacturing”, Chongqing Weichai needs leading product technology support, and also needs stable and united partners to provide professional consulting services.