In March 2024, on the eighth batch of national manufacturing individual champions list organized and recognized by the Ministry of Industry and Information Technology, Weiling Motor won the title and became one of the strength representatives in the global motor field. As a global supplier of core components for consumer appliances, GMCC and Welling not only continue to lead in the technology research and development and application of core components such as compressors and motors, but also ranked first in production and sales for many years. Taking Weiling motor as an example, its annual motor sales from 2020 has exceeded 200 million units, behind such a large-scale delivery “miracle”, how to achieve “quantity” and “quality”?

PLX82-EIP-PNC As a pillar of the real economy and a representative of the manufacturing industry, China’s home appliance manufacturing industry is currently undergoing a profound transformation. This is not only reflected in the high-end, intelligent and green trend of terminal products, but also through the accelerated upward upgrading of all links of the industrial chain and the improvement of quality and reliability. In the world’s largest air conditioning motor and washing motor production base in Foshan, Weiling Motor Shunde Factory (DC factory) took the lead in “breaking the game”, through a series of lean transformation, its DC factory has achieved a double jump in product quality and production efficiency, for the transformation and upgrading of home appliance manufacturing industry, rapid response to changes in end market demand. And work with customers to win market opportunities to set a new benchmark.

Process lean, build manufacturing upgrade of the body and bone

Weiling Motor Shunde factory (DC factory) has long maintained the world’s first DC motor market share, as an important parts supplier in the global home appliance industry, under the rapid growth of market demand, it is gradually facing the bottleneck period of production efficiency is difficult to continue to improve. Huang Gong, director of intelligent manufacturing in the DC area of Shunde Factory, said: “At the beginning of 2023, the DC area of Shunde Factory of Weiling Motor has determined the plan to increase production efficiency by 30% in this year, but the production capacity of the single line of the final assembly line is far from the target capacity, and the entire plant is facing relatively large pressure.”

After a detailed analysis of the operation of the production line, the DC plant found that the crux of the improvement of the overall efficiency of its production line lies in some key bottleneck positions. For example, some positions have a slow rhythm and become the “barrel short board” of the entire production line. Some links because of automatic induction adaptation problems, frequently cause the line body pause; There are also positions that are prone to product failure because of unreasonable feeding design… “Seeing the bottlenecks and even blocked points in these key links, we decided to actively promote the ‘four modernizations’ of the process, that is, de-defecation, de-instrumentalization, de-artificialization and automatization, so as to improve the overall production efficiency and ensure product quality with targeted improvements in each production link,” Huang said.

PLX82-EIP-PNC Taking the improvement of the tooling board in the final assembly process as an example, because there are many types of motor products that need to be manufactured, the level of flexibility of production is higher, and the DC plant area greatly improves the conversion efficiency by using the full-model compatible tooling board, and the debugging time is directly reduced from 15 minutes to “0”.

After a series of lean process innovation and optimization, Weiling Motor Shunde factory DC plant not only achieved substantial growth in output, but also to ensure the high-quality and stable delivery of products: on the one hand to achieve less human final assembly, unmanned parts, all positions to meet customer demand beats; On the other hand, for the new process, high precision and low value-added processes to achieve automation breakthroughs, successfully create the stators black light benchmarking area, the automation rate of the assembly increased from 65% to 87.5%, equipment utilization up to 100%, to achieve the optimal allocation of resources and maximize production efficiency.