Traditional aluminum processing enterprises embark on the path of digital intelligence
2024-06-13
Intelligent production organization, networked work in progress tracking, automated robot operations, and precise risk warning... Walking into Northeast Light Alloy Co., Ltd. (hereinafter referred to as Dongqing), which is known as the "silver pillar of the motherland", the first impression of reporters here is a "full sense of technology". During the 14th Five Year Plan period, Dongqing regards digital transformation as a key driving force for the high-quality development of high-end manufacturing, seizes the opportunity of information technology transformation, focuses on promoting the full integration of new intelligent manufacturing elements and the traditional aluminum processing industry chain, and deeply promotes enterprise transformation and upgrading in the process of building a "digital intelligent new Dongqing" to assist in the construction of new industrialization. "Intelligent manufacturing has promoted the reshaping and reconstruction of production organization by creating a smooth and interconnected digital workshop," said Qi Yan, Deputy Director of Dongqing Medium and Heavy Plate Factory. The medium thick plate factory where Qi Yan is located is the forefront of building high-precision and cutting-edge aluminum materials in China. Here, from the beginning of the rolling process, the production schedule, process requirements, and work report information of aluminum alloy ingots have been uploaded to the digital network platform. The intelligent system records the status of work in progress in real-time, achieving paperless tracking of the entire process without landing information. "The application of new technologies has made the production process control of Dongqing products more precise and efficient." Qi Yan said, "With the help of information systems, each material on the production line is assigned a unique identity code, and scanning the code can obtain all the 'resumes' of the corresponding product from initial feeding to packaging acceptance at each stage. At this point, the accuracy of on-site management has been directly positioned from the original' certain batch 'to a specific' certain one '. This not only ensures product quality, but also makes the upstream and downstream connections of the process smooth, fully stimulating the overall efficiency of the production system." With the increasingly perfect digital layout, Dongqing has issued orders through the inventory system, manufacturing execution system (MES) production scheduling, strict quality inspection system, and energy management system to assist production. "We are gradually establishing efficient and interconnected" digital workshops ". Various data captured from MES and equipment intelligent monitoring platforms are updated and bounced on the integrated control electronic screen next to key parts such as the plate shearing machine and the casting dispatch room, providing more clear and intuitive work guidance for on-site personnel. Coupled with intelligent tools such as intelligent robotic arms and unmanned refining vehicles, the "last mile" of online planning and execution is completely opened up. Since the intelligent transformation, Dongqing's overall production capacity, especially the production of high-end products, has repeatedly reached historical highs. The efficiency of some production lines has improved by nearly 30%, and the ability to ensure the supply of key materials in key areas has significantly improved. Building a safe and efficient digital intelligence ecosystem. In the first half of 2024, the Dongqing Digital Intelligence Round Ingot Processing Park was officially completed. On the aluminum alloy small and medium-sized round ingot production line in the park, robots with size and shape recognition functions do not require manual intervention. Through fully automatic positioning and grasping, they can complete the entire process of material filling, mechanical processing, and material stacking in a short period of time. Wang Xiaorui, the head of the equipment support team at Dongqing Melting and Casting Plant, introduced that before the intelligent transformation, all processes on the production line required manual participation, resulting in low efficiency and high-intensity repetitive labor. Robot operation not only ensures production progress and improves work quality, but also effectively alleviates the pressure of personnel allocation in positions. After the separation of humans and machines, the intrinsic safety of the site has also been significantly improved. Centered around safety and efficiency, the new era of Dongqing is constructing a comprehensive digital ecosystem, integrating automated and intelligent tools and methods into the "nerve endings" of production and operation. In the largest production main plate and strip factory of Dongqing, intelligent point inspection devices connected to the manufacturing system are distributed throughout the "key parts" of various work areas. Once abnormalities are detected, an alarm will be immediately issued. The device has been in use for 5 years and the factory has achieved a continuous record of "zero accidents". The device effectively maintains the safety and stability of production, providing support for the transformation of Dongqing's risk control mode from post response to pre warning. At Harbin Dongqing Special Materials Co., Ltd., regional engineer Zhu Chaodong demonstrated the LDC lean digital cloud platform on his phone. The reporter saw through the display interface that once the on-site risk points such as channel debris and pollution source leakage are submitted, the system backend will automatically conduct problem analysis and associate them with the responsible person. A clear task description and clear processing time limit work list will be generated as soon as possible, and the responsible person is required to implement rectification according to the time node. "Nowadays, this portable app allows us to check and fill in deficiencies anytime and anywhere, and fulfill our responsibilities anytime and anywhere. It has become an essential tool for our frontline employees to carry out daily work solidly. This not only enriches the application scenarios of Dongqing's digitalization, but also makes basic management and lean production concepts more deeply rooted in people's hearts," said Zhu Chaodong. The year 2024 marks the peak year of Dongqing's project construction and a crucial year for Dongqing to solidify its digital foundation and enter the future factory of intelligent manufacturing. As the "smart core" of manufacturing enterprises, the full coverage of MES production line has always been an important task for Dongqing's digital transformation. In 2024, the second phase of Dongqing MES project is being fully rooted in Dongqing Plate and Strip Factory and Harbin Dongqing Special Materials Co., Ltd. "The project is expected to be completed by the end of November. At that time, MES will fully leverage its central functions in various sectors such as aluminum alloy rolling, extrusion, forging, etc., and form a 1+1 gt; 2 amplification effect in conjunction with existing warehouse spare parts management systems, quality online detection systems, and other intelligent tools. This will accelerate the transformation of the old production methods of aluminum alloys and continuously expand the production and manufacturing capabilities of enterprise strategic guarantee products and competitive advantage products." Li Qiang, Chief Engineer of Dongqing Operation Management Department, told reporters. Starting from this year, Dongqing and China Aluminum Group High end Manufacturing Co., Ltd. have joined hands to launch a benchmark construction project of "Intelligent Chemical Plant" at Dongqing Medium and Heavy Plate Plant, adhering to demonstration and key research and development. In the process of project promotion, Dongqing actively linked with the new generation of industrial Internet big data platform, and carried out detailed planning and pilot on intelligent technologies such as automated information collection, homogeneous centralized control, AGV unmanned logistics, striving to seize the opportunity of a new round of industrial revolution with a more advanced and efficient operation and development mode, so as to realize the rediscovery and redevelopment of its high-end aluminum alloy manufacturing capacity. Intelligent manufacturing has extraordinary significance in building a 'century old Dongqing' with lasting vitality, strategic contribution, and social influence. We will base ourselves on the present and plan for the long term, truly improve and strengthen various tasks of digital upgrading and transformation, promote the improvement and efficiency of traditional aluminum processing and manufacturing industry, and accumulate momentum for accelerating the construction of world-class light alloy processing enterprises Zhang Rongwang, General Manager of Dongqing, Deputy Secretary of the Party Committee, and Leader of the Leading Group for Intelligent Manufacturing, said. (Lai Xin She)
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