CIMC Vehicles Achieves Significant Breakthroughs in Its “Upgrading of Production Lines”
Guests including Liu Hongqing (eighth from left), President of CIMC Tonghua Digital Semi-trailer Joint Company, attended the ceremony for launching the production
On the morning of July 28, the “super-Magellan digital production line” of Yangzhou CIMC Tonghua Special Vehicles Co., Ltd. (hereinafter referred to as CIMC Tonghua), the core plant of CIMC Vehicles (Group), was officially put into production in Yangzhou City, Jiangsu Province. It is understood that this production line has a different method of production and management compared to conventional ones and produces special vehicles in the approach used to manufacture commercial vehicles, with productivity largely enhanced and the delivery period significantly shortened, making itself a leading digital production line for special vehicles.
Setting a new benchmark- digital production line for special vehicles put into use in Yangzhou
Automated laser cutting work islands, digital welding lines, the world’s first automated robot spraying line for ultra-complex workpieces, the latest and most advanced KTL electrophoresis line… on the morning of 28, representatives of 100 customers, dealers and suppliers from across China witnessed the super-Magellan digital production line that was just put into use at the newly built digital semi-trailer plant of CIMC Tonghua and praised profusely about this new line which uses highly intelligent technologies.
“Previously, only production lines for commercial vehicles would be equipped with so many smart facilities. This is the first time for the production of special vehicles,” said Xu Yun, General Manager of Shanghai Lulutong Auto Sales Co., Ltd., He added that this production line would set a new benchmark for the smart manufacturing of the special vehicle sector.
According to Xia Aijun, General Manager of the digital semi-trailer plant of CIMC Tonghua, the Magellan coach plant project was officially approved in August 2016 and built at CIMC Tonghua. CIMC is the first company in China to explore and practice the smart manufacturing of special vehicles. With fast progress, the Magellan project was upgraded into the super- Magellan program with the completion of the entire process from laser cutting, robot welding to KTL electrophoresis, spraying coating and efficient assembling. Meanwhile, digital management systems such as PLM and MES are integrated into the line, achieving richer content and greater significance.
“With PLM and MES systems, informationized and digital management of the entire process from the product configuration during the early period, the product design, and structural design of techniques to the production at the site can be realized. Moreover, these systems can feed the data from the workshop back to the design end so that a closed loop for digital manufacturing of products can be achieved,” added Xia, “In this way, operational efficiency will be enhanced and the cycle from product development to market services and the delivery period will be shortened, bringing new vitality for the transformation of the market.”
tion- wastewater from coating can be used for fishery after special treatment
“The super-Magellan digital production line put into use today is a leading digital production line for special vehicles both within China and across the world,” said Dr. Li Xiaofu, Technical Director of CIMC Vehicles, “Through digital design, automated production, and digital management, the productivity will be significantly improved and the delivery period will be largely shortened, with zero emission of VOCs.”
It is reported that, with module work islands, this production line is capable of realizing flexible mixed production. “Module work islands” are new models suitable for flexible production when combining with module design of products. With the module configuration of products, limited modules can be used to meet the personalized needs of the customers.
“Simply put, it is to break away from the conventional concept of assembling lines and to produce different components of vehicles centrally. Then, these components will be assembled into the products required by the customers based on their orders just like stacking blocks,” explained Zhang Shiwei, Director of the automated manufacturing technology center of CIMC Vehicles, “In this way, we can not only meet the requirement for flexible production from the market but also significantly enhance our productivity.”
In terms of energy conservation and emission reduction, the reporters have seen in the plant that there was fish swimming in the water that was turned from the wastewater of coating after special treatment. “Previously, conventional primer coating processes were used for the production line of special vehicles with the wastewater generally containing ‘rusty water.’ With the new line, new technologies are applied for conserving energy and protecting the environment. The wastewater from multiple processes such as electrophoresis and coating can be used for fishery after special treatment,” explained the plant staff.
Planning for the future- invest in a complex for digital production and research on special vehicles
According to the analysis of related organizations in the industry, the special vehicle market in China is currently characterized by “multiple product varieties and limited quantities with small and fragmented manufacturers” in terms of the production and demands. With the accelerating of China’s economic growth and its development of infrastructure as well as the introduction of regulations such as GB1589 (limits of dimensions, axle load and masses for motor vehicles, trailers and combination vehicles) and GB7258 (technical specifications for safety of power-driven vehicles operating on roads), the market is in an increasingly need of special vehicles that are more specialized and smart with advanced technologies.
“The Magellan program was born against such backdrop,” said relevant official of CIMC, “The reason why CIMC Tonghua was chosen first for this mission is that it has a long history of manufacturing special vehicles and the strength in innovation.” It is understood that CIMC Tonghua is established in 1992 and has been focusing on the production of semi-trailers since its inception, with 26 years of experience in the manufacturing and R&D of semi-trailers. It boasts an annual designed capacity of 30,000 units. In 2017, the company has sold a total of 26,300 various special vehicles, ranking among the top in the industry.
The super-Magellan digital production line put into use on July 28 is a part of the complex for digital production and research on special vehicles invested by CIMC Group. It is reported that the construction of the complex was contracted officially in the development zone of Yangzhou City in November 2017. This project is a pilot one in the CIMC Industrial Park with a R&D center on semi-trailers and tank trucks, a digital manufacturing center, and a global operation center to be built, combining into a digital production and R&D complex for semi-trailers with a leading position in the Asia-Pacific region and a world-leading R&D and production base for tank trucks.
“The old plant of CIMC Tonghua located on Yangtse Road is expected to be relocated at the end of the next year,” explained Liu Hongqing, President of CIMC Tonghua Digital Semi-trailer Joint Company. The pilot complex for digital production and research on special vehicles has a total investment of RMB two billion and is expected to be completed in December 2019. Upon reaching its designed capacity, the project will realize an annual sales of RMB 3.6 billion and annual taxes of RMB 200 million. It will be an exemplary business for the smart manufacturing of semi-trailers and an iconic company in Yangzhou Economic and Technological Development Zone.