Machinery industry will enter the era of "big quality"

"Machinery industry" 13th Five-Year "quality management planning outline" (hereinafter referred to as the "planning outline") recently released in Beijing. On the background, process and main contents of the drafting of the outline of the plan, the reporter interviewed Wang Jianhe, vice president and Secretary General of the China Association of quality.

According to reports, the core of the "Planning Outline" is to firmly take the road of quality power. The "Planning Outline" aims to comprehensively improve the product quality and quality management level of the machinery industry, with the creation of world-renowned brands as the main line, supported by informatization, digitization, and intelligence, overall planning, and multiple measures to promote the realization of the scale of the machinery industry The historical leap from speed type to quality and efficiency type is to lay a solid foundation for quality management for the realization of a mechanical power.

Mechanical industry quality problems to be removed

Wang Jianhe said that in order to provide a scientific basis for formulating the "13th Five-Year Plan" for quality management of the machinery industry and accurately grasp the current situation of quality management of machinery industry enterprises, the China Machinery Industry Quality Management Association launched a sample survey of the current situation of quality management of machinery industry enterprises in 2014. The survey results show that China's machinery industry is "big but not strong", the leadership role is not strong, the quality of personnel is not high, the level of digitization and quality management is low, the four bases (basic materials, basic parts, basic technology and industrial technology foundation) are weak, and the problems such as poor product reliability are still prominent.

"As far as the entire machinery industry is concerned, poor reliability is still one of the more common quality problems." Wang Jianhe said that compared with similar products of the world's advanced level, poor product reliability is still a key factor restricting the "going out" of China's mechanical products. "Reliability improvement involves all aspects, not only technical issues, but also quality management throughout the life cycle." Wang Jianhe said to the reporter, "The machinery manufacturing industry should start from the 'four basic" to grasp the reliability. Every employee should be practical, the pursuit of excellence, strive for excellence, perfect."

China has gradually entered the era of "big quality"

After the founding of New China, especially since the reform and opening up, China's machinery industry on the basis of self-reliance, and actively absorb foreign advanced quality management experience, and gradually formed the characteristics of the machinery industry quality management methods.

In the early days of the founding of New China, China was in the period of planned economy, and quality management was mainly based on quality inspection. After the reform and opening up, the Ministry of Machinery Industry took the lead in introducing the concepts and methods of total quality management in developed countries, and organically combined the QC group activities with quality trustworthy teams to form a mass quality management form with the characteristics of the machinery industry. Starting from the actual action, the machinery industry has carried out the "process breakthrough" work with the main goal of stabilizing and improving product quality. Taking the release of ISO9000 standards as the starting point and carrying out quality certification, effectively promote the overall landing of total quality management.

In 2004, the national standard GB/T19580 "Criteria for Performance Excellence" was promulgated, which further expanded the connotation of total quality management and gradually entered the era of "big quality" in pursuit of excellent performance.

"Planning outline" pointed out that the importance of technology has become a fine tradition of machinery industry enterprises. The production process of mechanical products is long, the manufacturing process is complex, and there are many special processes, such as heat treatment, welding, spraying, equipment, etc., so the process requirements are high. As early as 1986, the machinery industry started from the reality of the industry and took the "process breakthrough" of strengthening process management and strict process discipline as an important starting point for the in-depth implementation of total quality management, and achieved good results.

Process management strengthened

In the long-term production practice, process management in the inheritance and innovation in the content of continuous enrichment, methods continue to improve, such as: 88.68 percent of the machinery enterprises process quota management; 84.91 percent of the machinery enterprises to identify the functional departments of the process and the key, special process assessment; 58.49 percent of the machinery enterprises to establish a process management system.

In addition to process management, reliability is an important quality characteristic of mechanical products. Wang Jianhe said: "The actual range of equipment machinery products is wide, and the requirements of reliability management are not balanced in various enterprises. Products such as machine tools, automobiles, electrical appliances and other products have higher requirements for product reliability." It is understood that the product reliability work of the electrical and electrical industry is one of the industries that have carried out relatively well in the mechanical equipment manufacturing industry. In addition to the electrical and electrical industry, the construction machinery industry also has enterprises that have done better in quality management.

Most of the quality management of Chinese automobile joint ventures is better. Wang Jianhe told reporters that due to the special requirements of the industry and the mandatory promotion of QS9000, ISO/TS16949 and other standards, especially the practical application of the five tools, the quality management level of the automotive industry is generally higher than that of other industries.

At the same time, he also pointed out that not all enterprises in the automobile industry have done a good job in quality management, among which automobile independent brands are inferior to joint venture brands in quality management.

There is a long way to go to improve product quality in an all-round way.

The machinery and equipment manufacturing industry involves many industries, and the quality management level of each industry is not balanced. In recent years, China's macroeconomic situation is tight, and the machinery industry has basically achieved moderate growth. According to the statistics of the National Bureau of Statistics, the added value of the machinery industry increased by 5.3 percent from January to November 2015, of which the automobile manufacturing industry increased by 13% in November.

However, while affirming the achievements, compared with advanced countries, China's machinery industry is large but not strong, the ability of independent innovation is weak, the key core technology and high-end equipment are highly dependent on foreign countries, and the innovation system is not perfect.

As far as the entire machinery industry is concerned, poor reliability is still one of the more common quality problems. Taking the machine tool in the equipment manufacturing industry as an example, the position of the machine tool industry in the machinery and equipment manufacturing industry is irreplaceable, but compared with advanced foreign companies such as Germany and Japan, the gap is also obvious. For example, the average trouble-free time of large milling machines in Europe and the United States is 300 hours, while the average trouble-free time in China is only 100 to 150 hours.

"Improving the reliability of mechanical products is not only a technical problem, but also a management problem. The improvement of reliability involves all aspects, not only technical problems, but also quality management of the whole life cycle." Wang Jianhe told reporters.

In recent years, China's construction machinery manufacturing industry has made great progress, but the core components (hydraulic parts, engines, electronic control systems) has been the biggest obstacle to China's construction machinery industry to the world's construction machinery industry commanding heights. Compared with international brands such as Carter and Komatsu, there is a certain gap in the dependence of core components of construction machinery on foreign countries and product reliability, and "full-life quality service" is still promising.

There are many reasons for the poor quality of parts. Wang Jianhe said that in the past, under the planned economic system, production enterprises focused on the main engine and the "four bases", design and technology, products and accessories, and sales and service. "Due to the high price of the whole machine, enterprises often focus on the whole machine when pursuing profits," Wang Jianhe said.

Wang Jianhe said frankly that at this stage, the machinery industry has insufficient high-end products and surplus low-end products. The embarrassing situation of "big but not strong" has not fundamentally changed. The machinery industry does not have a "Chinese brand" that is well-known internationally. The improvement cannot keep up with the growth rate of output, and there is still a long way to go to "comprehensively improve the quality of machinery industry products.

Enterprise quality management level to be improved

To implement the quality of the main responsibility of the enterprise, senior leadership is the key. The "National Machinery Industry Enterprise Quality Management Status Survey Report" shows that some business leaders and even senior leaders do not have enough awareness of quality, and quality awareness is still not strong, resulting in quality management in a mere formality. According to the data, only 43.64 per cent of enterprises have full-time senior quality managers, which directly affects the further implementation of quality responsibilities and the promotion of quality work.

Wang Jianhe said that the level of enterprise quality management also needs to be further improved. In a sense, the level of management is reflected in the refinement of management, as is the case for German companies and Japanese companies. Due to the limited quality of personnel, many enterprises in the machinery industry, especially small and medium-sized enterprises, are still at the "extensive" management level, which is far from the requirements of the future world "invisible champion.

If the quality cost is the quantitative embodiment of the quality management level, the cost of quality loss directly affects the profit of the enterprise. The survey shows that 27.78 per cent of enterprises still only count the costs incurred by substandard products without statistical analysis of quality costs, which is obviously not conducive to the further promotion of quality management.

It is understood that the current level of digital manufacturing is far from adapting to the "Made in China 2025." At present, informatization and Internet of Things technology are developing rapidly. Through informatization construction, product online detection, remote monitoring and full life cycle traceability can be effectively realized. Even if early product failures are found, product reliability can be improved, informatization and industrialization integration It has become the direction of my country's industrial development, and digital manufacturing is also the core content of the "Made in China 2025" planning outline.

China's economy continues to stabilize, has now entered the "new normal", to improve the quality of hedging economic slowdown has become an inevitable choice. However, the extensive mode of production in the machinery industry, weak basic development, low economic efficiency, insufficient investment in scientific research, and high dependence on external core technology are bound to affect and restrict the sustainable development of enterprises in the industry.

In order to ensure the realization of the quality management goals of the "13th Five-Year Plan" of the machinery industry, the "Planning Outline" puts forward the following suggestions: strengthen the construction of quality and the rule of law, promote the construction of enterprise informatization, strengthen the construction of quality brands, and strengthen the quality responsibility of the senior leaders of the enterprise. All kinds of quality management methods are inclusive, and the "four bases" are consolidated to make up for the quality "shortcomings".

Strengthen the construction of quality and rule of law

In the strategic layout of China's "four comprehensives", the concrete embodiment of comprehensively governing the country according to law in the field of quality is undoubtedly the construction of quality legal system. It is necessary to build a quality co-governance mechanism for the whole society, adhere to the guidance of standards and the legal system first, improve the legal system of quality work, increase the punishment of quality violators, and use legal means to solve outstanding problems and contradictions in quality development.

Establish and improve the quality and safety responsibility system of "local governments are responsible for the general principles, regulatory departments are responsible for their own responsibilities, and producers and operators are the first responsible persons", establish a quality responsibility traceability system and accountability system, and implement a lifelong quality accountability system. Consumers are encouraged to "vote with their feet" on products and services, report quality violations, make full use of market mechanisms to force quality improvement, and form a social atmosphere in which "everyone values quality, everyone creates quality, and everyone enjoys quality.

Promote the construction of enterprise information

Take "Made in China 2025" as an opportunity to promote the construction of enterprise information. The core of "Made in China 2025" is intelligent manufacturing. Enterprises should, in accordance with the requirements of the national "Special Action Plan for the Deep Integration of Informatization and Industrialization", incorporate the "integration of industrialization and industrialization" into the work schedule of enterprise management modernization, establish a management system in accordance with the "Requirements for Informatization and Industrialization Management System", and integrate R & D technology, management technology, automation technology and information technology effectively, promote the innovation of product R & D model and design concept, product manufacturing model and manufacturing method, business model and business process innovation, industrial chain system business model and win-win mechanism innovation to improve the core competitiveness of enterprises.

It is necessary to actively explore, practice and summarize the quality management methods and methods under the background of digital manufacturing, make full use of digital means to strengthen the collection, analysis, evaluation and decision-making of quality data, strengthen process control, product identification and traceability of the whole life cycle, and improve the effectiveness and efficiency of quality management.

Strengthen quality brand building

Strengthen the construction of quality brand from the actual situation of the industry. Under the guidance of the "brand cultivation management system" of the Ministry of industry and information technology, we should firmly establish the ideological consciousness of "rejuvenating the country by quality and strengthening the enterprise by brand", raise the brand construction to the strategic level of the enterprise, and closely combine the actual situation of the industry and the enterprise to promote the quality brand construction, and summarize the brand cultivation methods with industry characteristics in practice.

The core of the brand is quality. Enterprises should take the improvement of product quality as the foundation and core of their brand building, and run every link of product quality control through every link and every post of brand building; they should increase investment in scientific research and technological innovation, enhance the core competitiveness of enterprises, and provide technical support for increasing the stamina of enterprises and brand building; they should actively integrate with international standards, adopt foreign advanced standards and constantly improve the scientific and technological content of brands, make the brand building foundation more solid.

In addition, we should also pay attention to the integration of brand building and corporate culture construction, the integration of brand management system and the existing management system of the enterprise, increase brand publicity, insist on supporting the brand with culture, and inherit the culture with the brand, so as to achieve the integration of brand building system, corporate culture and management system, and inject soul into the brand.

Strengthen the Quality Responsibility of Senior Leaders in Enterprises

Enterprise is the main responsibility of product quality, improve quality in the final analysis depends on the enterprise itself. The "top leader" of an enterprise is the first person responsible for product quality. It is necessary to strengthen the study of quality laws, regulations, and policies, and raise the understanding of quality to the height of the foundation of a country and the foundation of a strong enterprise. Quality is the life of an enterprise. Implement quality brand strategy and continuously improve product quality and quality management level.

Quality management is also a "number one" project. The "top leaders" attach importance to the quality management of enterprises and do a good job. IS09001: The 2015 version of the new standard cancels the setting requirements for the establishment of management representatives, and the quality responsibilities of senior managers are strengthened accordingly. To implement the quality responsibility of senior managers, on the one hand, we should improve the system and mechanism, on the other hand, we should closely combine the performance indicators of senior leaders with the quality of products, so as to implement the quality responsibility of leaders.

An eclectic mix of quality management methods

Performance excellence-oriented, eclectic variety of quality management methods. Whether the method is good or not, the key lies in performance. Enterprises should combine the characteristics of the machinery industry and mechanical products, and actively promote advanced quality management methods such as excellent performance model, lean management, six sigma management, statistical process control, etc.

Machinery industry enterprises only from a practical point of view, a variety of quality management concepts, methods and tools, and in practice to summarize, form a set of suitable for their own characteristics, effective quality management methods, in order to continuously improve the effectiveness and efficiency of quality management, and internalized into the quality of the enterprise culture.

Consolidate the "four bases" to make up for the "short board" of quality"

Key basic materials, core basic components, advanced basic technology and industrial technology foundation are referred to as "four bases", which are the foundation and weak links of the machinery industry. To this end, the machinery industry should be guided by the "Guiding Opinions on Accelerating the Promotion of a Strong Industrial Foundation" issued by the Ministry of Industry and Information Technology in February 2014 to guide social resources, gather various forces, and make up for quality shortcomings.

　　

 

Through incentive funds, special subsidies or tax reductions and exemptions, enterprises, professional institutes, and colleges are guided and encouraged to carry out "four basic" research. We should strengthen the research on the important process links and the manufacturing of key parts that restrict the quality of products, so that enterprises can have sufficient technology accumulation and energy accumulation, and provide stamina guarantee for the development of enterprises with core technology.

In addition, enterprises should change their concepts and continuously increase investment in infrastructure, technological transformation and process equipment, gradually improve the degree of mechanization, intelligence and high-end manufacturing equipment, and ensure product quality through equipment and tooling. improve production efficiency and meet the requirements of high-quality production of products.

In 2015, the international situation is complicated, and the days of the machinery industry in various countries are not easy. China's machinery industry is under pressure, structural adjustment and transformation and upgrading have achieved initial results, and the main economic indicators have achieved positive growth. For the whole of last year, the added value of the machinery industry increased by 5.5 percent over the same period last year; revenue from its main business was 22.98 trillion billion yuan, up 3.32 percent over the same period last year; and total profits were 1599.238 billion billion yuan, up 2.46 percent over the same period last year.