China's machinery industry will enter the era of "high quality"

The "13th Five-Year Plan for Quality Management of the Machinery Industry" (hereinafter referred to as the "Planning Outline") was released in Beijing recently. Regarding the background, process and main contents of the drafting of the "Planning Outline", the reporter interviewed Wang Jianhe, the vice president and secretary general of the China National Machinery Association.
According to reports, the core of the "Planning Outline" is to firmly follow the road of quality and power. The "Planning Outline" aims to comprehensively improve the quality and quality management of machinery industry products, and to create a world-renowned brand as the main line, with information, digital and intelligent as the support, overall planning, and multiple measures to promote the scale of the machinery industry. The historical leap from speed type to quality and efficiency has laid a solid foundation for quality management in order to realize mechanical power.

The quality of the machinery industry is in jeopardy. Wang Jianhe said that in order to provide scientific basis for the 13th Five-Year Plan for the quality management of machinery industry and accurately grasp the status quo of quality management of machinery industry enterprises, China Machinery Industry Quality Management Association launched the quality of machinery industry enterprises in 2014. The current status of the management of sample survey work. The survey results show that China's machinery industry is “big but not strong”, the leadership is not strong, the quality of personnel is not high, the level of digitization and quality management is low, and the four bases (basic materials, basic components, basic processes and industrial technology base) are weak. Problems such as poor product reliability are still outstanding.
"As far as the entire machinery industry is concerned, poor reliability is still one of the more common quality ills." Wang Jianhe said that compared with the world's advanced level of similar products, poor product reliability is still the key to restricting China's machinery products "going out". factor. “Reliability improvement involves all aspects, not only technical issues, but also quality management throughout the life cycle.” Wang Jianhe told reporters, “The machinery manufacturing industry should start with the 'four basics' to grasp the reliability. Every employee must Work hard, pursue excellence, strive for excellence, and perfection."

China has gradually entered the "mass" era. After the founding of New China, especially since the reform and opening up, China's machinery industry has actively absorbed advanced foreign quality management experience on the basis of self-reliance and gradually formed a quality management method characteristic of the machinery industry.
At the beginning 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 the quality trustworthy team to form a mass quality management form with mechanical industry characteristics; In actual practice, the “Technology Breakthrough” work with the main goal of stabilizing and improving product quality was carried out; the ISO9000 standard was released as a starting point, and the quality certification was effectively promoted, which effectively promoted the comprehensive landing of total quality management.
In 2004, GB/T19580 "High Performance Evaluation Standards" national standards were promulgated, the connotation of total quality management was further expanded, and gradually entered the era of "high quality" in pursuit of high performance.
The "Planning Outline" pointed out that attaching importance to craftsmanship 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 actual situation of the industry, and strengthened the “process breakthrough” of 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 is strengthened In the long-term production practice, process management is continuously enriched and continuously improved in the process of inheritance and innovation, such as: 88.68% of machinery enterprises carry out process quota management; 84.91% of machinery enterprises define process functions and conduct Key and special process evaluation; 58.49% of machinery companies have established process management systems.
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 for reliability management are not balanced among enterprises. For example, machine tools, automobiles, electrical appliances and other products have higher requirements on product reliability." It is understood that products of the electrical and electronic industry Reliability work is one of the better industries in the mechanical equipment manufacturing industry. In addition to the electrical and electronic industry, the construction machinery industry also has better companies in quality management.
Most of the quality management of Chinese auto 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 major tools, the quality management of the automotive industry is generally higher than other industries.
At the same time, he also pointed out that not all companies in the automotive industry have done a good job in quality management, and the auto brands are inferior to the joint venture brands in quality management.

Comprehensive improvement of product quality has a long way to go . There are many industries involved in the machinery and equipment manufacturing industry, and the quality management level of each industry is not balanced. In recent years, China's macroeconomic situation has been 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% from January to November 2015, of which the automobile manufacturing industry increased by 13% in November.
However, at the same time of affirming achievements, compared with advanced countries, China's machinery industry is large but not strong, its independent innovation capability is weak, and key core technologies and high-end equipment are highly dependent on foreign countries and the innovation system is imperfect.
For the entire machinery industry, poor reliability is still one of the more common quality ills. Taking the working machine tool in the equipment manufacturing industry as an example, the machine tool industry has an irreplaceable position in the mechanical equipment manufacturing industry, but compared with advanced foreign companies such as Germany and Japan, the gap is also obvious. For example, the average time between failures of large milling machines in Europe and America is 300 hours, while the average time between failures in China is only 100 to 150 hours.
“Improving the reliability of mechanical products is both a technical issue and a management issue. Reliability improvement involves all aspects, not only technical issues, but also quality management throughout the 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) have always been the biggest obstacle to hinder China's construction machinery industry to the commanding heights of the world's engineering machinery industry. Compared with international brands such as Carter and Komatsu, there is a certain gap between the core components of construction machinery and the dependence on foreign products and product reliability. The "life-long 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, the “five light and five heavy” phenomenon of heavy-duty “four basics”, heavy design light craftsmanship, heavy product light fittings and heavy sales of light services was serious. "Because of the high price of the whole machine, enterprises often focus on the whole machine when pursuing profits," said Wang Jianhe.
Wang Jianhe admits that at this stage, the high-end shortage of machinery industry products and the low-end surplus, the "big but not strong" embarrassing situation has not fundamentally changed, and the machinery industry has no internationally acclaimed "Chinese brand". The improvement can not keep up with the growth rate of production, and there is still a long way to go to "improve the quality of machinery industry products."

The quality management level of enterprises needs to be improved to implement the quality responsibility of enterprises, and senior leadership is the key. The "Investigation Report on the Status Quo of Quality Management of National Machinery Industry Enterprises" shows that some enterprise leaders and even senior leaders have insufficient understanding of quality and quality awareness is still not strong, resulting in quality management in the form. According to the data, only 43.64% of the companies have full-time quality senior management, 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 needs to be further improved. In a sense, the level of management is reflected in the management refinement, as is the case with German companies and the same for Japanese companies. Due to the limited quality of personnel, many enterprises in the machinery industry, especially small and medium-sized enterprises, still stay in the "extensive" management level, which is far from the requirements of the future world "invisible champion".
If the quality cost is a quantitative representation of the quality management level, the quality loss cost directly affects the profit of the enterprise. According to the survey, 27.78% of enterprises only count the expenses incurred by substandard products, but not the statistical analysis of quality costs, which is obviously not conducive to the further advancement of quality management.
It is understood that the current level of digital manufacturing is still far from adapting to "Made in China 2025". At present, information technology and Internet of Things technologies are developing rapidly. Through information construction, products can be effectively detected online, remotely monitored and traceable throughout the life cycle. Even if early faults of products are discovered, product reliability, informationization and industrial integration can be improved. It has become the direction of China's industrial development, and digital manufacturing is also the core content of the "Made in China 2025" planning outline.
China's economy has continued to stabilize and has now entered the "new normal". It is an inevitable choice to hedge the economic slowdown with quality improvement. However, factors such as extensive production methods in the machinery industry, weak basic development, low economic returns, insufficient investment in scientific research, and high dependence on core technologies are bound to affect and constrain the sustainable development of industrial enterprises.
In order to ensure the realization of the “13th Five-Year” quality management objectives of the machinery industry, the “Planning Outline” puts forward the following suggestions: strengthen the construction of quality rule of law, promote the construction of enterprise information, strengthen the construction of quality brands, and strengthen the quality responsibility of senior leaders of enterprises. Eclectic collection of various quality management methods, consolidating the "four basics" to fill the quality "short board."

Strengthening the construction of quality and rule of law In China's "four comprehensive" strategic layout, the concrete manifestation of the comprehensive management of the country in the quality field is undoubtedly the construction of quality and legal system. It is necessary to build a quality-rule mechanism for the whole society, adhere to the standard guidance, the rule of law, improve the legal system of quality work, increase the punishment for quality violations, and use legal means to solve outstanding problems and contradictions in quality development.
Establish and improve the quality and safety responsibility system of “the general rule of local government, the responsibility of the regulatory authorities, and the first responsible person of production and management”, establish a traceability system and accountability system for quality responsibility, and implement a lifelong system of quality accountability. Encourage consumers to “vote with their feet” on products and services, report quality violations, make full use of market mechanisms, and push for quality improvement, and form a social atmosphere in which “everyone values ​​quality, everyone creates quality, and everyone enjoys quality”.

Promote enterprise information construction and take "Made in China 2025" as an opportunity to promote enterprise information construction. The core of "Made in China 2025" is smart manufacturing. Enterprises should, in accordance with the requirements of the National “Integrated Action Plan for Deep Integration of Informatization and Industrialization”, incorporate “two integrations” into the work schedule of enterprise management modernization, establish a management system in accordance with the requirements of “Informatization and Industrialization Management System Requirements”, and develop R&D technologies. Management technology, automation technology and information technology are effectively integrated, and the innovation of product development model and design concept, innovation of product manufacturing mode and manufacturing method, innovation of business model and business process, business model of business chain system and innovation of win-win mechanism are promoted through application. Improve the core competitiveness of enterprises.
It is necessary to actively explore, practice and summarize the quality management methods and methods in the context of digital manufacturing, and make full use of digital means to strengthen the collection, analysis, evaluation and decision-making of quality data, and strengthen the traceability of process control, product identification and life cycle, and improve quality. Management effectiveness and efficiency.

Strengthen the construction of quality brands and strengthen the construction of quality brands from the actual situation of the industry. Guided by the “Brand Cultivation Management System” of the Ministry of Industry and Information Technology, we firmly established the ideology of “Quality Rejuvenating the Country and Strengthening the Brand”, raising the brand building to the strategic level of the enterprise, closely integrating the industry and enterprises to promote the quality brand building, and summing up in practice. Industry-specific brand cultivation methods.
The core of the brand is quality. Enterprises should regard improving product quality as the foundation and core of their brand building, and each link of product quality control should be carried out in every link and every position of brand building; it is necessary to increase scientific research input and technological innovation to enhance core competition of enterprises. The ability to provide technical support for increasing the company's stamina and brand building; to actively integrate with the international standards, the use of foreign advanced standards to continuously enhance the brand's scientific and technological content, so that the brand building foundation is 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 the brand propaganda, adhere to the culture to support the brand, inherit the culture with the brand, and achieve the brand building system and enterprise. Integration of culture and management systems, injecting soul into the brand.

Strengthening the quality responsibility of senior leaders of enterprises is the responsibility of product quality. In the final analysis, it depends on the enterprise itself. The “top leader” of the 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 awareness of quality to the foundation of the country and the foundation of strong enterprises. Quality is the life of the enterprise, and Implement quality brand strategy and continuously improve product quality and quality management.
Quality management is also the “top leader” project. Upside-down, the quality management work of the “top-ranking” enterprise is doing a good job. IS09001: The new version of the 2015 version cancels the setup requirements for the establishment of management representatives, and the quality responsibilities of senior managers are strengthened accordingly. To implement the quality responsibility of senior management, we must improve from the system and mechanism. On the other hand, we must closely integrate the performance indicators of senior leaders with the quality of products, so that the quality responsibility of leaders can be implemented.

Eclectic and quality management methods are guided by high performance and eclectic methods of quality management. The method is good, the key is performance. Enterprises should combine the characteristics of the machinery industry and mechanical products to actively promote advanced quality management methods such as high performance model, lean management, Six Sigma management, and statistical process control.
Mechanical industry enterprises can only improve the quality management effectiveness and efficiency by summarizing the concepts, methods and tools of various quality management, and summarizing and forming a set of effective quality management methods suitable for their own characteristics. Efficiency and internalization into the quality culture of the company.

Consolidate the "four basics" to fill the quality "short board"
The key basic materials, core basic components, advanced basic processes and industrial technology foundation are referred to as the “four basics”, which are the foundation and weak link of the machinery industry. To this end, the machinery industry should be guided by the Ministry of Industry and Information Technology's "Guiding Opinions on Accelerating the Industrial Strong Base" issued in February 2014 to guide social resources, gather various forces, and fill the shortcomings of quality.
Guided and encouraged enterprises, professional institutes and institutions to carry out “four basics” research through reward funds, special subsidies or tax exemptions. We should increase research efforts on important process links that restrict product quality and the manufacture of key components, so that enterprises have sufficient technology accumulation and energy accumulation to provide a stamina for mastering the development of core technology enterprises.
In addition, enterprises should change their concepts, continuously increase investment in infrastructure, investment in technological transformation, and investment in process equipment, gradually increase the degree of mechanization, intelligence, and high-end manufacturing equipment, ensure product quality and improve production efficiency through equipment and tooling. To meet the requirements of high quality production of products.
In 2015, the international situation was complicated and the days of machinery industry in various countries were not good. China's machinery industry is under pressure, structural adjustment and transformation and upgrading have achieved initial results, and major economic indicators have achieved positive growth. For the whole year of last year, the added value of the machinery industry increased by 5.5% year-on-year; the main business income was 22.98 trillion yuan, a year-on-year increase of 3.32%; the total profit was 159.238 billion yuan, a year-on-year increase of 2.46%.

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