Crack the industry problem and establish the Dongfeng brand
"‘These five beams are much better than the imported parts in terms of size and appearance quality! The beam or Dongfeng mold is doing very well. We have eight beams ready to be handed over to Dongfeng Mould!’ This was a statement made by Jiangling Motors Co., Ltd., when Xu Xu, the frame manager, addressed Li Benyan, the chief engineer of Dongfeng Mould Manufacturing Technology."
Project weight: 25 parts, 85 sets of molds
The Jiangling V348 mold project was a "bulk" mold development and manufacturing project signed between Jiangling Motors Co., Ltd. and Dongfeng Auto Mould Co., Ltd. at the end of June 2005. A total of 25 parts and 85 sets of molds were involved, with shipments delivered in three batches from October last year, strictly following the contract terms. As of June 10, after two years, all third batch molds for the Jiangling V348 project had been successfully delivered to the users.
"The characteristics of this mold project include a large number of beam parts—up to 10 in total. Therefore, during the design and development phase, the first priority was optimizing the stamping process and mold structure design, while also predicting and addressing issues like rebound and distortion that could occur during actual debugging. Additionally, during the manufacturing and debugging process, we needed to develop reasonable solutions, as beam parts are highly sensitive to press pressure and mold clearance. Any small change in the part can lead to significant size variations, requiring repeated modifications and adjustments," explained Ren Qian, director of the mold adjustment workshop.
"The second challenge was the top cover mold, which measures 4 meters in length and has a depth of 0.4 meters. This is the largest cover mold our company has ever undertaken," he added.
High difficulty: One part required seven rounds of debugging
The issue of beam rebound is a well-known challenge in the mold industry. "During the debugging of the beam parts, staff members like Zhou Bo and Zhou Yuchun faced difficulties with complex parts but never gave up. They went through multiple rounds of testing, feeding parts repeatedly until they finally solved the most challenging issue—part deformation. Problems such as side pulling on the parts kept arising, and one single part went through as many as seven rounds of modification, taking six months to resolve," said Li Cheng, director of the Jiangling project.
Hua Lianhan, marketing manager, shared an interesting story about the project. "At one point, Jiangling users, frustrated with the slow progress, invited a Turkish mold expert for a special consultation. However, the proposed solution didn’t help. Despite this, we didn’t give up and maintained our commitment to the user. Under the guidance of Li Benyan, the team worked together and eventually overcame the challenges."
Sunge, one of the beam components, used his technical expertise to solve the problem during mold debugging. When the user saw the final product, they were impressed with the accuracy of the dimensions, which even exceeded those of the KD parts. They said, "Dongfeng’s workers are amazing!"
More than 40 pages and 200 items revised
Mold production is a technology-intensive process, based on user needs and continuous improvement. After the mold was completed, it went through acceptance by the user, and further adjustments were made to ensure better customer satisfaction and alignment with the user's production schedule. To adapt to the user's equipment and conditions, mold rectification became a critical step in improving part quality.
In February of this year, the Jiangling mold project acceptance team began inspecting the third batch of molds. For this, the clamp adjustment workshop dispatched six elite staff to form the Jiangling Project Rectification Team, led by Lu.
"For two consecutive months, Lu led five team members to debug and adjust over 30 sets of molds. To meet the tight deadlines, the team took on the task of adjusting the Yamashita press as their 'own.' In a situation with limited manpower and time, they completed more than 40 pages of rectification work involving over 200 sub-items!" said Lu Zhigang, the dispatcher of the clamp adjustment workshop.
Near the press in the workshop, the author found Lu, who was currently delivering molds to Nissan. With a strong presence and a hearty laugh, he recalled the intense days of the Jiangling project. "It was exhausting, but when we finally sent off the third batch of JMC molds, the sense of pride was overwhelming."
"At that time, we worked day and night. We accompanied the users during the day for inspections, and at night, we made the necessary adjustments. The next morning, we re-accepted the molds again. Every day was filled with hard work for four months. There were even weeks when I left home at 11 or 12 at night and returned to work at 8 the next morning," Lu said, looking at the mold.
"On a Sunday morning, Lu fell asleep during a project meeting at the marketing department. After the meeting, the head of the Jiangling acceptance inspection team was distressed. It turned out that Lu’s team had taken the initiative to let him rest," said Yang Xiaoshui, a member of the Jiangling rectification team.
"In this way, I spent half a day playing with my kids to make up for the time I missed with them," Lu smiled brightly.
"Through the joint efforts of all the employees of Dongfeng Mould, we ensured the forming quality and stability of our products, met the production requirements, and overcame the long-standing rebound problem of beam parts. I was deeply moved by the philosophy of being responsible to our users," said the head of the Jiangling acceptance team sincerely.
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