Crack the industry problem and establish the Dongfeng brand

"‘These five beams are much better in both product size and appearance quality compared to the imported parts! 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, spoke to 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 and Dongfeng Auto Mould in late June 2005. A total of 25 parts and 85 sets of molds were involved, with shipments delivered in three batches starting 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 accepted by users. "The characteristics of this mold project include a large number of beam parts—up to 10 in total. Therefore, during the development and design phase, the first priority was to optimize the stamping process and mold structure design, and to predict potential issues like rebound and distortion during actual debugging. Second, during the manufacturing and debugging process, we needed to develop reasonable solutions because beam parts are highly sensitive to press pressure and mold clearance. Even small changes can significantly affect part dimensions, requiring repeated modifications and adjustments." Mr. Ren Qian, director of the company’s mold adjustment workshop, shared more details. “The second key component is the top cover mold, which is 4 meters long and has a depth of 0.4 meters. This is the largest cover our mold company has ever undertaken.” 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 stringer parts, staff like Zhou Bo and Zhou Yuchun faced complex rebound problems but never gave up. They repeatedly tested and adjusted the parts until the most difficult issues, such as side pulling, were resolved. One part went through as many as seven rounds of modification, taking six months to complete,” said Li Cheng, director of the Jiangling project. Hua Lianhan, marketing manager, shared an anecdote about the project. “At one point, Jiangling users invited a Turkish mold expert to visit and consult on the debugging challenges. However, the proposed solutions didn’t resolve the issues. Despite this, we never gave up. With the guidance of Chief Division Li Benyan and the team’s determination, we eventually overcame the difficulties.” Sunge, one of the beam components involved in the debugging, relied on his daily experience to identify the root cause and find a solution. When the user saw the final product, they were impressed, saying, “Dongfeng workers are amazing!” More than 40 pages and over 200 items for rectification. Mold production is a highly technical process, based on user needs and continuous improvement. After the molds are completed, user acceptance is crucial to ensure satisfaction and alignment with their production schedules. To adapt to the user’s equipment and conditions, mold rectification becomes a vital step in improving part quality. In February, the Jiangling mold project acceptance team began inspecting the third batch of molds. For this, the clamp adjustment workshop sent six elite members to form the Jiangling Project Rectification Team, led by Lu. “For two consecutive months, Lu and five team members debugged and rectified over 30 molds. To meet tight deadlines, they even took on Yamashita’s press adjustments as ‘exclusive’ tasks. Under low manpower and time constraints, they completed more than 40 pages of rectification work involving over 200 subitems,” said Lu Zhigang, the dispatcher of the clamp adjustment workshop. Near the press in the workshop, the author found Lu giving the mold to Nissan. Tall and handsome, always smiling, he recalled the intense days of the Jiangling rectification. “It was tiring, but seeing the third batch of JMC molds being handed over filled me with pride.” “During that time, we worked alongside users during the day for inspections and corrected their feedback at night. We would re-inspect the next morning and continue working late into the night. Every day was a battle for four months. In February, I often returned home at 11 or 12 and came back at 8 the next day,” Lu said, looking at the mold. “On a Sunday morning, Lu attended a project meeting and fell asleep during it. After the meeting, the head of the inspection team was distressed, thinking Luc was staring at them. But instead, the team offered him a break,” added Yang Xiaoshui, a member of the Jiangling rectification team. “I spent half a day playing with my kids to make up for the time I missed,” Lu smiled. “Through the joint efforts of all Dongfeng Mould employees, we never gave up on the user and cracked the challenging problem of beam part rebound. We ensured the forming quality and stability of the products, meeting the user’s production requirements. I am deeply moved by the philosophy of being responsible to the users,” said the head of the Jiangling acceptance team sincerely.

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