When Mr. Liang Guihua, Chairman of Xipai Group Co., Ltd., made this decision in 2019 to invest in the construction of a high-end automated production line for high-precision valve parts that weigh more than several thousand kilograms and have a batch size of at least 10 pieces, almost everyone in the company was criticized. Opposition from senior management and doubts from peers: "Isn't it just grandstanding to automate such a small batch?" "How can automation be realized for various types of valves with different specifications and special materials?" "How to ensure product quality"... …Now, three years later, this flexible production line, which integrates 6 high-end machining centers and is nearly 100 meters in length, is the largest flexible production line in the Asia-Pacific region suitable for multi-variety and small-batch production. It has doubled its production efficiency and increased its production capacity. The outstanding performance of 40% reduction in personnel has shattered all doubts, and it has also become the "fixing needle" for Xipai Intelligent Dream Factory, laying a solid foundation for it to become one of the most complete high-end valve manufacturing companies in China.
"For manufacturing companies, if they want to be better, they must have their own unique advantages. For Xipai, I think it is intelligence." Mr. Liang Guihua said, "Anchoring lights-out factories and digital factories, Xipai is exactly Taking this flexible line as a starting point, we will continue to exert efforts to continuously strengthen the core barriers for future manufacturing challenges."
Aiming at multi-variety and small batches, Asia-Pacific’s largest hybrid flexible production line
Founded in 2009, Xipai is a high-end intelligent enterprise focusing on fluid control solutions. It has been engaged in the R&D and production of special equipment for oil drilling and production, pipeline valves, control valves, and instrumentation. With its high performance and high precision Our products have become first-tier suppliers for leading energy companies such as PetroChina, Sinopec, Kuwait National Oil Company (KOC), Abu Dhabi National Oil Company (ADNOC), Algeria SONATRACH, etc., and have high visibility and influence in the industry.
Walking into Xipai's factory in Jinhu, Jiangsu, you will be amazed by its advanced level, whether it is the modern factory building with cutting-edge design, the intelligent and efficient production equipment, automated production lines, or the futuristic data monitoring hall. As a provincial leader said during the visit, "I did not expect Jinhu to have such an advanced enterprise, let alone such an entrepreneur with advanced ideas." Behind all this, it is inseparable from its helmsman, Mr. Liang Guihua. Deep and forward thinking.
"Competition will only become more intense. On the one hand, there are two-way attacks by domestic giants and overseas brands. On the other hand, user needs are changing rapidly. Only by taking the intelligent route can Xipai have a 'differentiated competitive advantage'. A few years ago, we started planning until I met Fastems in 2019." Mr. Liang Guihua said, "Through Fastems' many successful cases around the world, I saw what the flexible production line I imagined would look like; after many in-depth discussions, I truly felt the difference of Fastems. ', they can always put themselves in my perspective and win my trust."
It is worth mentioning that Xipai’s flexible production line not only sets a record in terms of length, but the hybridity and complexity of its production line are also second to none in the industry. The first is the mixing of machine tools of different brands. The Seipai production line integrates six four-axis four-linkage machining centers of different specifications and models from Okuma and Makino brands. This not only requires the production line integrator to have strong brand compatibility capabilities, but also Requires extensive application experience. One difficulty is also a highlight: the mixing of pallets of different sizes and functions. In order to match the two types of machine tools, the 159 machining pallets in the production line have two very different sizes, namely 630*630mm table horizontal adding and 800*800mm table horizontal adding. In addition, there are 118 1200*800mm. Material wooden pallets, the flexible line needs to intelligently identify each pallet and accurately send them to the corresponding material station or machine tool, which is also a big test for the performance of the flexible control software.
Mr. Ding Yongping, general manager of Fenfa Automation Shanghai Co., Ltd., said: "Different brands of machine tools, different pallet sizes, mixed lines and material pallet management have never been the 'patent' of any company, and Fastems can undertake this project and ensure the production line The certainty and confidence of smooth operation all come from our rich experience in the field of automation for more than 40 years. Which brand of machine tools is equipped with what interface, how does the palletizer switch to identify pallets of different sizes, and how does the flexible control software meet the needs of different users? needs, the answers to these questions have been successfully verified countless times in our thousands of cases around the world. Moreover, the installation and commissioning of the Xipai flexible line this time were all completed by our Chinese service team, which has achieved a high degree of customer satisfaction Recognition, this is also a strong proof of Fastems China's positioning of 'global technical standards, local response speed'."
The Fastmes flexible line uses a pallet interaction form. The parts, fixtures and pallets move within the line as a whole, thus enabling rapid switching of different parts in the production line. In addition, when a part is being debugged, clamped, and inspected, the flexible line can automatically switch to other parts for processing, greatly improving equipment utilization. "
Flexible lines also reduce the number of operators and workload. Thanks to the Fastems software, as long as the processed products are put online, if they are repeated in the future, production can be restarted with one click, realizing the inheritance of the process. Fastems software informs operators in advance of all production resources needed to ensure continued production before production begins. Xipai achieved ‘the longest FMS line with the fewest people’!
As one of the most important industries driving world production, oil and gas extraction equipment has always been considered a relatively backward area of intelligent construction. On the one hand, the characteristics of the product itself, such as multiple varieties, large volume, long manufacturing process, and high degree of customization, make the data in the production process prone to fragmentation and require very high automation and digital technology solutions. On the other hand, due to the high investment in oil and gas equipment and the difficulty in integrating resources, it is more difficult to achieve full-process intelligent production. However, these challenges in the eyes of outsiders have become the driving force for the Xipai Group, which has high goals and dares to make breakthroughs, to move forward.
"The MMS production control and management software configured in the Fastems flexible line can fully meet the digital needs of Xipai. First of all, it can realize automatic order scheduling and automatic adjustment of orders when encountering urgent orders or equipment failures, plus real-time and detailed order progress. The monitoring system can truly help users achieve uninterrupted production. Secondly, MMS can also be easily connected to the company's data network to achieve real-time collection and monitoring of data on all production factors of the production line, such as machine tools, cutting tools, fixtures, pallets, etc., providing Process optimization, production management, and even enterprise management provide scientific data support." Mr. Ding Yongping added.
The transparency of data allows Xidui to see at a glance the pre-production preparation of production factors, order progress, bottleneck elimination and machine tool OEE. Production and processing no longer only relies on the technical level and application experience of personnel, but a standardized operating process and a programmed process plan. No matter who you are, as long as they follow the data, they can produce the same high-quality products. This advantage can greatly reduce the workload of operators in actual processing. As Mr. Chen Hui said, when the flexible line processes already produced products, there is no need to repeat debugging, and the data can be retrieved directly in the software. In the long run, it brings the possibility of future replication of Xipai’s digital factory on a global scale.
"The flexible line is the turning point of Xipai, and it is also the starting point. We plan to replicate it in other traditional workshops in one or two years, when the production line runs more smoothly and the process and team are more mature, so that the entire factory can' Be smart. We also look forward to continuing to work together with world-leading technical forces like Fastems to contribute to the high-quality development of China's energy equipment manufacturing industry and the Chinese energy machinery brand's overseas expansion."
