Current Situation and Countermeasures of Localization of Car Tools in China

The localization of car knives is a common strategic issue for China's car industry and tool industry. The car industry is becoming a pillar industry in China. 1 The contribution to national GDP is gradually increasing. At present, the automobile industry has a pivotal position in many countries, such as the US auto industry accounting for 1.6% of GDP, the German auto industry accounting for 3% of GDP, and the Chinese auto industry accounting for 0.8% of GDP. The Chinese auto industry during the "10th Five-Year Plan" period The proportion of GDP will also increase substantially, which will certainly drive the rapid development of China's energy, transportation, machinery manufacturing, materials, electronics and other industries. 2 Great contribution to improving social employment. According to the data, every job created in the auto industry can drive 10 to 15 people in related industries to work, which can boost the efficiency of upstream and downstream industries by 6 to 7 times. In China, although the automobile industry currently accounts for only 0.8% of GDP, the number of employed people in the automobile and related industries accounts for 1/7 of the total number of urban employment in China. 2. The localization of car knives is an effective way to reduce the cost of domestic cars and improve production efficiency. China's car industry is still in a disadvantage in international competition under the circumstances that China's car industry is not fully equipped with vehicle development capabilities. As the WTO approaches, the domestic car industry will face greater international competition. In order to meet the fierce market challenges, it is urgent to further develop the localization of car knives, reduce the production cost of cars, and enhance the competitiveness of the WTO. According to some data, the input of 3% of the production cost will lead to an increase of 15-20% in production efficiency. 3. The localization of car knives is an important part of the auto industry's independent technology development system strategy. The technical status of car cutters (tools) reflects to a certain extent the technical level of a country's car products, car production technology and CNC machining technology. The more advanced car production and processing technology and automatic production line have promoted the use of new advanced tools and special production equipment updated with numerical control technology. The progress of the car machining process technology has always been spirally rising, driving the development of cutting tools, machine tools and related technologies to meet the needs of large-scale, low-cost, high-efficiency industrial production of cars. The localization of car knives is a scientific and technological work. In fact, it is a social system engineering. Based on the domestic tool industry, the high-tech starting point, and the implementation of the localization of advanced car knives, it is not only focused on solving the current domestic tools for introducing car production lines. Supply problems and reduce production costs; it is also one of the important strategic measures to establish the medium and long-term development of China's car manufacturing industry technology independent development system, laying a solid scientific and technological foundation for the sustainable development of China's automobile industry and other machinery manufacturing industry. The model of technological transformation will also drive the rapid advancement of science and technology in the fields of new advanced cutting tools, tool materials, CNC special production equipment, computer technology and automatic control technology. 4. The localization of car tools has made it possible for the rapid development of the national tool industry. 1 The car producing country is also a big tool producer. In developed countries, the proportion of tool costs continues to rise, accounting for 2 to 4% of manufacturing costs. According to statistics, in 2000, the output of China's cars reached 600,000, and the value of the tools used in the car production line for one year was 400 million yuan. From a foreign perspective, the world's largest car producing country is also a large tool producing country, and its car cutters share 30% to 40% of the country's total tool production. Japan, the United States and Germany not only account for 50-60% of the world's automobile production, but also account for 50-60% of the world's machine tool output value. The output value of American auto cutters is 9-10 billion US dollars, Japan is 700-800 million US dollars, and Germany is 600-700 million US dollars. It accounts for 40% of the total tool market, and Japan and Germany also reach about 35%. It has formed a group of specialized tool factories and tool products that are closely related to the automobile industry, which strongly supports the sustainable development of the automobile industry. 2 The localization of car knives will promote the comprehensive improvement of the technical level of products in China's tool industry. The localization of car knives will certainly drive the rapid advancement of science and technology in the basic research, product development, technological transformation and asset restructuring of China's tool industry, promote industrial restructuring, and form scientific research, development, production, supply, service, etc. in the tool industry. The new market structure in all aspects guides social science and technology collaboration and tool technology to be in line with international standards and compete in the international market. It will also drive China's tool materials, tool structure, tool dynamic balance and safety technology, difficult material processing mechanism, cutting database and expert diagnostic knowledge system, CNC special equipment, CNC production automatic line machining technology, monitoring and measurement system technology, etc. The research and development of science and technology is developing at a high speed. It is hard to imagine that the manufacturing giants like China rely on foreign imports for their tools in the automotive industry. 3 The localization of car knives provides a huge market for China's national tool industry. The localization of car knives is not only beneficial to domestic car manufacturers, but also will drive the development of China's tool market. During the "7th Five-Year Plan", "Eighth Five-Year Plan" and "Ninth Five-Year Plan" period, the tool industry carried out a certain scale of equipment and technology improvement, and introduced some advanced CNC machine tools and numerical control systems. According to statistics, due to various reasons, China The utilization rate of CNC machine tools is less than 37% in developed countries. At present, most of the tools and high-end instruments used in domestic car production lines and CNC machining rely on foreign countries, which not only increases the manufacturing cost, but also restricts the development of China's national industry. 5. The state actively supports the implementation of localization of car knives. In May 1998, the National Science and Technology Commission Comprehensive Planning Division approved the plan of the National Precision Tools Engineering Research Center (hereinafter referred to as the Engineering Center). The localization of car knives is the planning task of the engineering center. An important part of the book. The Ministry of Science and Technology attaches great importance to this work, instructing the National Precision Tools Engineering Technology Research Center (referred to as the Engineering Center) on the basis of previous work, this year's work focus is to further improve the localization of car tools, do their best Speed ​​up the work process. Second, the implementation of the localization of car knives Situation 1. Progress of localization of car knives. The National Precision Tools Engineering Technology Research Center (hereinafter referred to as the Engineering Center) started the localization of car knives from 1997. For more than three years, the leadership of relevant government departments. With the support and cooperation with the relevant parties, the Engineering Center has made certain progress in the research, propaganda and organization and implementation of the work philosophy based on the industry, limited goals, step-by-step implementation, and point-to-face. The work has been carried out from the single-handed development of the tools of the "Jida" car production line, and has developed into a pattern of full-scale advancement of tools for the FAW-Volkswagen, Shanghai Volkswagen and other car engine manufacturers and the full participation of the tool industry, and continues to move towards this. Direction development 1 Focus on the localization of tools for FAW-Volkswagen "Jedda" production line. The cumulative number of tools delivered to FAW-Volkswagen has reached more than 210 specifications, accounting for 35%, of which 116 specifications have replaced the imported tools. According to the former Ministry of Machinery Industry on the sedan The overall requirements for the localization of art equipment, the focus of the localization of car tools is directed at the FAW-Volkswagen "Jedda" car production line. From March to April 1997, the tooling department of the FAW-Volkswagen Planning Department, the purchasing department and the engineering center - The joint investigation team of relevant personnel of Chengdu Tool Research Institute took the "Zhida" production line tool localization pilot and selected intentions, and adopted the "Automotive Tool Localization Seminar" and the in-depth tool factory field research method. Inspected some of the backbone factories (companies) of China's tool industry. Through field research, members of the joint inspection team have a more comprehensive understanding of the tool industry, collecting and obtaining a large amount of information about the localization of tools. In August of the same year, in the FAW- Under the overall arrangement of Volkswagen, Chengdu Tool Research Institute organized and participated in the trial production of various tool factories, and carried out on-the-spot investigation and preliminary surveying and mapping work on some technical parameters and usage of imported tools in some "Jedda" production lines. Larger tools, samples provided by FAW-Volkswagen, for the trial manufacturers to return to the factory Step mapping test. At the same time, the three parties reached an agreement on the time schedule of the tool mapping, drawing approval, tool inspection, on-line test and tool localization identification and acceptance. This kicked off the localization of FAW-Volkswagen's knives. Through nearly three years of hard work, this work has achieved stage results. So far, Chengdu Tool Research Institute has organized Chengdu Measuring Tool Co., Ltd., Harbin Industrial Group, Hanjiang Tools Factory, Chongqing Tool Factory, Hunan Diamond Company, Siping Tools Factory, Harbin Xingyu Company, Shaanxi Aviation Carbide Tools Company. , Guangzhou Tool Factory, Tsinghua Fangda Ceramic Tool Company and many other tool factories have developed car-car broach holders, blades, indexable turning tools, machine clamp drills, face milling cutters, gear hobs, radial shaving cutters. , HSK composite boring tool, CBN blade, solid carbide composite hole processing tool, HSK hydraulic chuck and other tools localized work, the cumulative delivery of tools to FAW-Volkswagen has reached more than 210 specifications, accounting for 35%, of which , 116 specifications of the tool has replaced imports. 2 Actively promote the localization of Shanghai Volkswagen "Santana" car knives. In the second engine plant, 224 specifications and knives have been localized, saving 3 million knives and accessories, accounting for 10% of the total knives and accessories. At the same time, the knives and accessories have been reduced. Inventory and liquidity have shortened the supply cycle of knives and accessories. Shanghai Volkswagen Automotive Co., Ltd. is a joint venture between Shanghai Automotive Industry Corporation and Volkswagen AG. The newly built engine plant II uses the same production process as FAW-Volkswagen. The process technology and equipment of the production line are from Volkswagen AG. The introduction of the company, the two processes are basically the same, and FAW-Volkswagen is the representative of the most advanced technology level in China's current car production. Therefore, the localization of Shanghai Volkswagen engine production tools is also of great significance. In April 1998, Chengdu Tool Research Institute was the leading product, technical strength and level, key equipment, quality assurance system and testing equipment, supply capacity, asset status, industry positioning, and enterprise for 15 major domestic automotive tool and measuring tool manufacturers. A comprehensive survey was conducted in the evaluation and other aspects, and the “Investigation Report on the Major Automobile Tools, Measuring Tools and Measuring Instruments Manufacturers in the Tool Industry” was submitted to Shanghai Volkswagen Engine Factory. In June 1998, the Chengdu Tool Research Institute successfully completed the tool professional training for the relevant engineering and technical personnel of Shanghai Volkswagen Engine Factory. The Chengdu Tool Research Institute specially compiled the teaching materials for this training and hired relevant domestic tool professionals. The experts went to Shanghai to give lectures, and various production lines of Shanghai Volkswagen Engine Factory sent people to participate in the training and achieved good results. In order to promote the localization of car tools and ensure the quality of domestically produced tool products, the engine manufacturer of Shanghai Volkswagen Co., Ltd. entrusted the National Tool Quality Supervision and Inspection Center (hereinafter referred to as the "Knife Inspection Center") and its supporting unit Chengdu Tool Research Institute to be responsible for the domestic production. The quality of chemical tool products is supervised, inspected and certified. The tool inspection center will carry out technical appraisal of the localized tools according to the category of the tool products and according to the production verification of the tools in Shanghai Volkswagen and the inspection results of the quality of the samples sent by the tool products. Through the technical identification of the tool, the tool inspection center will issue the certificate of localized tool quality certification, and as the basis for the Shanghai Volkswagen Engine Factory to use such domestically produced tools. From April to October 1998, Chengdu Tool Research Institute recommended Tsinghua Fangda Ceramic Tool Company and Chongqing Yulun Ceramic Tool Company to Shanghai Volkswagen Engine Factory according to the specific situation of the localization of FAW-Volkswagen tool in 97 and 98. , Harbin Xingyu Company, Hunan Diamond Carbide Tool Company, Siping Tools Factory, Hanjiang Tools Factory, Harbin Measuring Tool Group Co., Ltd. and many other car tool manufacturers, and assisted in the development of CBN tools, ceramic tools, gear tools and overall hard Trial production of alloy tools. From August to October 1998, according to the intention agreement reached between Chengdu Tool Research Institute and Shanghai Volkswagen Company, Chengdu Tool Research Institute and the National Tool Quality Supervision and Testing Center jointly cooperated with Hunan Diamond Company and Chengdu Tool Research Institute Superhard Tool Center. On-the-spot review and certification of production equipment and tooling, precision inspection, technical documentation and process control, raw material procurement and tool production verification of car knives, and issued a certificate. On February 5-6, 1999, the "Second Cars Localization Seminar and the 1998 Shanghai Volkswagen Car Tool Localization Work Summary Meeting" was held in Shanghai. The relevant leaders of the Ministry of Science and Technology and the National Machinery Bureau, Shanghai Volkswagen Company and Engine Factory Relevant leaders attended the meeting, and some of the shareholder units of the Engineering Center and some key enterprises in the tool industry attended the meeting. The meeting summarized the progress of the implementation of the localization of Shanghai-Volkswagen "Santa?" car knives and accessories since April 1998. By 1999, the second engine of the engine had 224 varieties of knives. The auxiliary equipment has achieved localization, saving 3 million yuan in knives and accessories, accounting for 10% of the total cost of knives and accessories. At the same time, it has reduced the inventory of knives, accessories and liquidity, and shortened the knives and accessories. The supply cycle (see the table below for the localization of Shanghai Volkswagen Knives and accessories) 2. Problems in the localization of car knives 1 In the localization of car knives for several years, although some achievements have been made, There are many difficulties in work and problems that need to be solved urgently. The main problem is: in the implementation of this work, due to the lack of necessary organizational unified leadership and effective measures, there are often inconsistent steps in the work, the plan is not compact, and the lack of effective Communication, quality service is not enough, etc. It affects the process of localization of car tools. 2 Inadequacies: China's car tool independent development capability is insufficient; lack Research on common technology; specialized production has not formed scale. Third, the next step of the localization of car tools 1. Strengthen the leadership of the localization of car tools. Car tool localization is a social system engineering, which involves It is not a unit that can be completed independently. It is necessary to establish an organizational form that can coordinate all parties, so that the localization of car knives can be implemented in an organized and step-by-step manner with the strong support of relevant state departments. To ensure the smooth progress of this work, the project center and the various car (steam) car manufacturers, tool factories and other parties have extensive consultations, and reached a consensus, it is proposed to set up a leading group for the localization of car tools, the team members from the higher authorities, Chengdu It is composed of many domestic production enterprises such as Tool Research Institute, FAW Volkswagen, Shanghai Volkswagen, Shenlong Fukang, etc. From the experience of localization of car knives for several years, we know the complexity and difficulty of the work, to ensure the smooth work. In addition to the full cooperation of the manufacturers, Must be strongly supported and assisted by the superior unit. 2. Determine the work objectives and implementation plan of each stage. 1 Cooperate with each factory to formulate the work plan and arrangement for the localization of car tools. According to the work status and current needs of the previous stage, determine the domestic car tool this year. Relevant work items such as specific projects, progress targets, screening and fixed-point factories. 2 Regularly hold technical seminars for car factories, engineering centers, and tool factories to strengthen work contacts, analyze and deal with the information and problems of car tool localization at any time, and drop the work to the work. 3. Promote the localization of car knives and promote the achievements of advanced knives. 3. Coordinate all parties and work together. 1 Production coordination. The supporting unit of the engineering center: Chengdu Tool Research Institute (hereinafter referred to as the tool institute) is a tool of China. The only professional office in the industry has high prestige and industry management experience in the industry. At the same time, it has a relatively wide technical cooperation relationship with related industries such as machine tools, and has familiarity with related industries. It has the coordination ability of both the supply and demand sides of the tool. The engineering center can give priority to supporting and recommending specialized production sites (bases), and can also organize these enterprises to undertake a complete set of car production tool transformation localization projects. 2 organize scientific and technological research. Chengdu Tool Research Institute--The Engineering Center not only has close contact with both the supply and demand sides of the tool, but also has more information and technical links with relevant universities and research institutes. With the support of relevant state departments, Chengdu Tool Research Institute--Engineering Center can organize a variety of scientific seminars to study and solve a series of basic theories in the localization of car tools. Common technical problems: its focus on tool materials ? Tool structure? Tool dynamic balance and safety technology? Difficult to machine workpiece material cutting mechanism? Cutting database and expert diagnosis system? CNC production automatic line machining technology? Special equipment? Monitoring and measurement system and other scientific and technological fields. Fundamentally, the digestion of imported tools and production line technology, the simple imitation of car cutters is self-developed. Chengdu Tool Research Institute--The Engineering Center can organize the horizontal joint of tool factory and machine tool professional factory, and vigorously develop all kinds of professional machine tools for producing CNC tools, especially those of CNC machine tools that produce tool holders. Speed ​​up the pace of tool production equipment replacement and improve the matching capacity of domestic tool-specific equipment. 4. Strengthening the provision of specialized services for automobile companies 1 Extensively carrying out quality service work. Chengdu Tool Research Institute--Chengdu Tool Testing Institute of Engineering Center (composed of National Tool Quality Supervision and Inspection Center and Machinery Industry Department Measuring Instrument Monitoring and Testing Center), with powerful testing instrument and rich quality management experience. It can provide car manufacturers with quality information of tool measuring instrument products, and at the same time provide car manufacturers with quality certification services for tool suppliers. For example, Shanghai Volkswagen Automotive Co., Ltd. has undertaken the quality certification work of many tool suppliers. The work was fully affirmed by Shanghai Volkswagen Automotive Co., Ltd. Through extensive exchanges, we seek more extensive cooperation and services with tool manufacturers and automobile manufacturers in the quality supervision of tools and measuring instruments. In accordance with the ISO9000 assessment standard, the Chengdu Tool Testing Institute will take the lead to further determine the quality assurance system for the localization of car tools, jointly grasp the quality of domestically produced tools, and formulate relevant project procedures and contents for quality assessment. Chengdu Tool Research Institute--In the work of promoting the application of domestic car knives, the Engineering Center can train cutting-edge technology and tool knowledge for the first-line operators of the automobile factory to improve the technical level of tool use. From the point and the surface, we will consolidate the results of the localization of car knives and transform scientific and technological achievements into productivity as soon as possible. 5. Exchange of experience and communication of information. 1 Strengthen leadership, unify planning, sum up the domestic work of car knives in the previous stage, affirm the results, find out the deficiencies, and provide relevant information and basis for further development of car knives localization. 2 Leading the group, establish a localization cooperation network for car tools, gradually absorb the tool factories with better conditions, further implement the fixed-point factory for fixed car tools, establish a stable supply and demand partnership, and create a car tool supply system in China. 3 Regularly report the progress of the localization of car knives to the Ministry of Science and Technology and the State Economic and Trade Commission, so as to fully implement the industrialization project of China's car knives and improve the level of technology and products of the national tool industry with the support of the state.

IV. Concluding remarks The domesticization of car knives in China is a scientific and technological work. It is actually a social system engineering. The car industry is a technology-intensive pillar industry in China. It is necessary to develop and adopt advanced knives with high efficiency, high reliability and high precision. Based on the domestic market, the localization of tools as soon as possible is a common problem faced by the automobile manufacturing industry and the tool industry. Grasp the good opportunity, relying on the leadership and support of the relevant ministries (bureaus) of the State, relying on the National Precision Tools Engineering Technology Research Center (Limited Co., Ltd.) to change concepts and mechanisms, relying on the absorption and absorption of foreign advanced technologies, relying on The overall advantage of the tool industry, closely cooperate with the automotive industry, to establish an independent development system for China's car manufacturing industry technology. Only in this way can we adapt to the rapid development of the automobile industry and realize the grand goal of "the promotion plan of the automobile industry", thereby promoting the improvement of the technical level of the entire tool industry and machinery manufacturing industry. For the specifications of some types of tools that cannot be domestically produced at the moment, we should set the company, set the factory, and introduce foreign products and technologies in a targeted manner to achieve the goal of complete supply of complete sets of tools.

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